U.S. patent application number 15/753444 was filed with the patent office on 2018-08-30 for air and water barrier article with porous layer and liner.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Rajan B. Bodkhe, Daniel R. Fronek, Taylor M. Seabaugh, Martin J. Widenbrant.
Application Number | 20180245332 15/753444 |
Document ID | / |
Family ID | 56940337 |
Filed Date | 2018-08-30 |
United States Patent
Application |
20180245332 |
Kind Code |
A1 |
Widenbrant; Martin J. ; et
al. |
August 30, 2018 |
AIR AND WATER BARRIER ARTICLE WITH POROUS LAYER AND LINER
Abstract
There is provided an article that includes a polymeric layer
disposed on and covering a first major surface of an porous layer,
an adhesive layer disposed on a second major surface of the elastic
layer opposite the polymeric layer; and a liner disposed on a major
surface of the polymeric layer opposite the first major surface of
the elastic layer. The polymeric layer and the porous layer
together form an air and water barrier that is water vapor
permeable. The liner is water vapor impermeable. In a preferred
embodiment the polymeric layer comprises a polyoxyalkylene polymer
having at least one end group derived from an alkoxy silane. A
method of applying the article to a surface of a building component
is also provided.
Inventors: |
Widenbrant; Martin J.;
(Stillwater, MN) ; Seabaugh; Taylor M.; (Stanford,
CA) ; Fronek; Daniel R.; (Woodbury, MN) ;
Bodkhe; Rajan B.; (Woodbury, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
56940337 |
Appl. No.: |
15/753444 |
Filed: |
August 18, 2016 |
PCT Filed: |
August 18, 2016 |
PCT NO: |
PCT/US2016/047630 |
371 Date: |
February 19, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62206348 |
Aug 18, 2015 |
|
|
|
62268563 |
Dec 17, 2015 |
|
|
|
62376202 |
Aug 17, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 3/26 20130101; B32B
5/18 20130101; B32B 5/024 20130101; C09J 2471/006 20130101; B32B
3/266 20130101; B32B 2307/7246 20130101; B32B 5/026 20130101; B32B
2419/00 20130101; B32B 5/32 20130101; B32B 2307/7265 20130101; B32B
7/02 20130101; C09J 2400/263 20130101; C09J 2471/005 20130101; E04B
1/665 20130101; B32B 27/08 20130101; B32B 5/245 20130101; B32B
2307/51 20130101; B32B 2307/7244 20130101; B32B 5/26 20130101; B32B
7/12 20130101; C09J 7/26 20180101; C09J 7/29 20180101; B32B 7/06
20130101; B32B 2307/724 20130101; B32B 27/12 20130101; B32B 2255/26
20130101; B32B 2307/7242 20130101; C09J 7/21 20180101; C09J
2400/243 20130101; B32B 2307/748 20130101; B32B 5/022 20130101;
B32B 2405/00 20130101; E04B 1/625 20130101; C09J 2301/18 20200801;
B32B 2305/026 20130101; C09J 2433/00 20130101; B32B 27/065
20130101 |
International
Class: |
E04B 1/62 20060101
E04B001/62; E04B 1/66 20060101 E04B001/66; B32B 3/26 20060101
B32B003/26; B32B 27/06 20060101 B32B027/06 |
Claims
1. An article comprising: a polymeric layer disposed on and
covering a first major surface of an elastic porous layer, wherein
the polymeric layer and the elastic porous layer together form an
air and water barrier that is water vapor permeable; an adhesive
layer disposed on a second major surface of the elastic porous
layer opposite the polymeric layer; and a liner disposed on a major
surface of the polymeric layer opposite the first major surface of
the elastic porous layer, wherein the liner is water vapor
impermeable.
2. The article of claim 1, further comprising a coating composition
disposed between at least a portion of the polymeric layer and the
liner, wherein the coating composition has a first peel adhesion to
the liner that is lower than a second peel adhesion between the
polymeric layer and the liner.
3. The article of claim 2, wherein the second peel adhesion is at
least 15 N/dm.
4. The article of claim 2, wherein the liner is cut at a location
corresponding to an edge of the coating composition.
5. The article of claim 2, wherein the liner does not cover the
coating composition.
6. An article comprising: a polymeric layer disposed on and
covering a first major surface of an elastic porous layer, wherein
the polymeric layer and the elastic porous layer together form an
air and water barrier that is water vapor permeable; an adhesive
layer disposed on a second major surface of the elastic porous
layer opposite the polymeric layer; and a liner disposed on a major
surface of the polymeric layer opposite the first major surface of
the elastic porous layer, wherein the liner is water vapor
impermeable and covers only a portion of the major surface of the
polymeric layer.
7. The article of claim 6, wherein the article passes at least one
of Modified Test 1 of ASTM D-1970/D-1970M-13, Modified Test 2 of
ASTM D-1970/D-1970M-13, or Modified Test 3 of ASTM
D-1970/D-1970M-13.
8. The article of claim 6, wherein a portion of the air and water
barrier not covered by the liner has a vapor transmission rate of
greater than or equal to 1 perms.
9. The article of claim 6, wherein the elastic porous layer
comprises at least one of a plurality of elastomeric strands,
elastic net, elastic nonwoven material, elastic woven fabric,
elastic knitted fabric, elastic foam, elastic microperforated film,
and combinations thereof.
10. The article of claim 6, wherein the article has an elongation
of at least 90% in at least one direction.
11. The article of claim 6, wherein the polymeric layer comprises a
polyoxyalkylene polymer having at least one end group derived from
an alkoxy silane.
12. The article of claim 11, wherein all of the end groups of the
polyoxyalkylene polymer are silyl terminated.
13. The article of claim 6, wherein the elastic porous layer
comprises at least one of polyester, polylactic acid, polyolefin,
polyamide, polyurethane, or rayon.
14. A method of applying an air and water barrier article, the
method comprising: adhering at least a portion of the adhesive
layer on a roll of the article of claim 1 to a surface of a
building component, so that the article is affixed to the surface
of the building component; unwinding at least a portion of the
roll, wherein during the unwinding, the liner remains disposed on
the major surface of the polymeric layer opposite the first major
surface of the elastic porous layer; and, peeling at least a
portion of the liner away from a portion of the article.
15. The method of claim 13, further comprising leaving a portion of
the liner disposed on the major surface of the polymer layer.
16. The article of claim 4, wherein the elastic porous layer
comprises at least one of a plurality of elastomeric strands,
elastic net, elastic nonwoven material, elastic woven fabric,
elastic knitted fabric, elastic foam, elastic microperforated film,
and combinations thereof.
17. The article of claim 4, wherein the article has an elongation
of at least 90% in at least one direction.
18. The article of claim 4, wherein the polymeric layer comprises a
polyoxyalkylene polymer having at least one end group derived from
an alkoxy silane.
19. The article of claim 18, wherein all of the end groups of the
polyoxyalkylene polymer are silyl terminated.
20. The article of claim 4, wherein the elastic porous layer
comprises at least one of polyester, polylactic acid, polyolefin,
polyamide, polyurethane, or rayon.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application Nos. 62/206,348, filed Aug. 18, 2015; 62/268,563, filed
Dec. 17, 2015; and 62/376,202, filed Aug. 17, 2016, the disclosures
of which are incorporated by reference in their entirety
herein.
FIELD
[0002] The present disclosure also relates to articles that are
water vapor permeable and air and water barriers.
BACKGROUND
[0003] Air barrier systems control movement of air, and
specifically water vapor, across a surface of a structure, such as
a building enclosure. In exterior walls, uncontrolled air flow is
the greatest source of moisture and condensation damage. Indoor
comfort is affected by air temperature, relative humidity,
direction of airflow and surrounding surface temperatures. Indoor
air quality is enhanced by air barrier systems by efficiently
keeping pollutants out of building interiors. Pollutants include
water vapor, suspended particulates, dust, insects, and smells, for
example. Air barrier systems have significant impact on electricity
consumption and gas bills. Air barrier systems in nonresidential
buildings are estimated to reduce air leakage by up to 83 percent,
reduce heating bills more than 40% and reduce electricity
consumption more than 25% according to simulations by the National
Institute of Standards and Technology (NIST) compared to typical
buildings without air barriers. Water vapor is a key ingredient in
corrosion and mold growth. Air barrier systems help prevent water
vapor from being transported by air movement between exteriors and
interiors of structures, such as buildings.
[0004] The use of air barrier systems has been a requirement in
Canada for almost 25 years and is becoming important in North
America due to net zero energy requirements by 2030, required by
the US Army Corp of Engineering, ASHRAE 90.1, and International
Energy Conservation Code--2009. On Dec. 16, 2011, the DC
Construction Codes Coordinating Board (CCCB) adopted the 2012
International Energy Conservation Code (IECC).
[0005] Some membrane sheets having both waterproofing properties
and moisture permeability are known. One typical example of such
moisture-permeable waterproofing sheets is flash-spun nonwoven
fabrics. U.S. Pat. No. 3,169,899 (Steuber), for example, discloses
a flash-spun nonwoven fabric. U.S. Pat. No. 3,532,589 (David)
discloses a method for producing a flash-spun nonwoven fabric. The
nonwoven fabric thus obtained has an appropriate pore size to block
liquid water but allow water vapor to pass through. A known example
of the nonwoven fabric is commercially available under the trade
designation "Tyvek" from E. I. Du Pont de Nemours and Company,
Wilmington, Del. USA, which is obtained by thermo-compressing a
three-dimensionally-meshed fiber of high-density polyethylene. Such
a moisture-permeable waterproofing sheet can prevent external
liquid water from infiltrating through the sheet, but can vent
water in vapor form.
SUMMARY
[0006] However, openings such as windows or doors are not flat. It
is difficult to form a waterproofing layer only with a
waterproofing sheet, and therefore the opening is often finished
with a waterproofing tape with a pressure sensitive adhesive layer
provided thereon. In this case, since the most commonly used
pressure sensitive adhesives often are made of rubber or asphalt
materials, the moisture permeability of the entire tape decreases,
and the same moisture retention problem as that of a common
waterproofing sheet can occur.
[0007] Mechanical fasteners, can be used to affix the
moisture-vapor permeable waterproofing sheet on substrates of
exterior walls. As a result, moisture may permeate from gaps of
such fasteners, such as nail holes, over a long period of time. It
is beneficial for such moisture-vapor permeable waterproofing
sheets to pass ASTM D-1970/D-1970M-13 or similar modified tests
such as Modified Test 1 of ASTM D-1970/D-1970M-13, Modified Test 2
of ASTM D-1970/D-1970M-13, Modified Test 3 of ASTM
D-1970/D-1970M-13, or combinations thereof for nail
sealability.
[0008] It is also beneficial for adhesives provided on these air
and water barrier articles to provide robust adhesion in a variety
of conditions. For example, it is beneficial for such an adhesive
to adhere to wet substrates, which are common conditions on
surfaces of building components at a construction site. There
exists a need for an air and water barrier article that, when wound
in a roll with a release liner, provides appropriate release from
the article and an adhesive used to coat at least a portion of the
article to provide easy application of the air and water barrier
article to substrates, such as building components. There is also a
need for these air and water barrier articles to provide acceptable
permeability performance with respect to water vapor according to
ASTM E96/E96M-13.
[0009] In one aspect, the present disclosure provides an article
that includes a polymeric layer disposed on and covering a first
major surface of an elastic porous layer, an adhesive layer
disposed on a second major surface of the elastic porous layer
opposite the polymeric layer, and a liner disposed on a major
surface of the polymeric layer opposite the first major surface of
the elastic porous layer. The polymeric layer and the elastic
porous layer together form an air and water barrier that is water
vapor permeable. The liner is water vapor impermeable. At least a
portion of the article covered with the liner is vapor impermeable
and an air and water barrier.
[0010] In another aspect, the present disclosure provide an article
that includes a polymeric layer disposed on and covering a first
major surface of an elastic porous layer, an adhesive layer
disposed on a second major surface of the elastic porous layer
opposite the polymeric layer, and a liner disposed on a major
surface of the polymeric layer opposite the first major surface of
the elastic porous layer. The polymeric layer and the elastic
porous layer together form an air and water barrier that is water
vapor permeable. The liner is water vapor impermeable covers only a
portion of the major surface of the polymeric layer. At least a
portion of the article covered with the liner is vapor impermeable
and an air and water barrier.
[0011] In another aspect, the present disclosure provides a method
of applying an air and water barrier article. The method includes
adhering at least a portion of the adhesive layer on a roll of the
article described above to a surface of a building component, so
that the air and water barrier article is affixed to the surface of
the building component. The method includes unwinding at least a
portion of the roll. During the unwinding, the liner remains
disposed on the major surface of the polymeric layer opposite the
first major surface of the elastic porous layer. The method also
includes peeling at least a portion of the liner away from a
portion of the self-sealing article. In some embodiments, the
method includes leaving a portion of the liner disposed on the
major surface of the polymer layer.
[0012] Various aspects and advantages of exemplary embodiments of
the present disclosure have been summarized. The above Summary is
not intended to describe each illustrated embodiment or every
implementation of the present disclosure. Further features and
advantages are disclosed in the embodiments that follow. The
Drawings and the Detailed Description that follow more particularly
exemplify certain preferred embodiments using the principles
disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The disclosure may be more completely understood in
consideration of the following detailed description of various
embodiments of the disclosure in connection with the accompanying
figures, in which:
[0014] FIG. 1 is a side cross section view of an embodiment of an
air and water barrier article according to the present
disclosure;
[0015] FIG. 2 is a side cross section view of another embodiment of
an air and water barrier article according to the present
disclosure;
[0016] FIG. 3 is a side cross section view of still another
embodiment of an air and water barrier article according to the
present disclosure;
[0017] FIG. 4A is a side cross section view of an embodiment of an
air and water barrier article having a microporous membrane
according to the present disclosure;
[0018] FIG. 4B is a side cross section view of another embodiment
of an air and water barrier article having a microporous membrane
according to the present disclosure;
[0019] FIG. 5 is a schematic representation showing the manufacture
of an elastic air and water barrier article according to some
embodiments of the present disclosure;
[0020] FIG. 6 is a representation in plan view of a portion of an
air and water barrier article according to the present
disclosure;
[0021] FIG. 7 is a side cross section view of an embodiment of a
roll of a linered air and water barrier article according to the
present disclosure;
[0022] FIG. 8 is a side cross section view of another embodiment of
a roll of a linered air and water barrier article according to the
present disclosure;
[0023] FIG. 9 is an end cross section view of an embodiment of a
roll of a linered air and water barrier article according to the
present disclosure having a coating composition; and
[0024] FIG. 10 is a top view of a portion of a linered air and
water barrier article according to the present disclosure.
[0025] While the above-identified drawing, which may not be drawn
to scale, sets forth various embodiments of the present disclosure,
other embodiments are also contemplated, as noted in the Detailed
Description. In all cases, this disclosure describes the presently
disclosure by way of representation of exemplary embodiments and
not by express limitations. It should be understood that numerous
other modifications and embodiments can be devised by those skilled
in the art, which fall within the scope and spirit of this
disclosure.
DETAILED DESCRIPTION
[0026] As used in this specification, the recitation of numerical
ranges by endpoints includes all numbers subsumed within that range
(e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.8, 4, and 5, and the
like).
[0027] Unless otherwise indicated, all numbers expressing
quantities or ingredients, measurement of properties and so forth
used in the Specification and embodiments are to be understood as
being modified in all instances by the term "about." Accordingly,
unless indicated to the contrary, the numerical parameters set
forth in the foregoing specification and attached listing of
embodiments can vary depending upon the desired properties sought
to be obtained by those skilled in the art utilizing the teachings
of the present disclosure. At the very least, and not as an attempt
to limit the application of the doctrine of equivalents to the
scope of the claimed embodiments, each numerical parameter should
at least be construed in light of the number of reported
significant digits and by applying ordinary rounding
techniques.
[0028] For the following defined terms, these definitions shall be
applied for the entire Specification, including the claims, unless
a different definition is provided in the claims or elsewhere in
the Specification based upon a specific reference to a modification
of a term used in the following Glossary:
Glossary
[0029] The words "a", "an", and "the" are used interchangeably with
"at least one" to mean one or more of the elements being
described.
[0030] The term "layer" refers to any material or combination of
materials on or overlaying a substrate.
[0031] Words of orientation such as "atop, "on," "covering,"
"uppermost," "overlaying," "underlying" and the like for describing
the location of various layers, refer to the relative position of a
layer with respect to a horizontally-disposed, upwardly-facing
substrate. It is not intended that the substrate, layers or
articles encompassing the substrate and layers, should have any
particular orientation in space during or after manufacture.
[0032] The terms "about" or "approximately" with reference to a
numerical value or a shape means+/-five percent of the numerical
value or property or characteristic, but expressly includes the
exact numerical value. For example, a viscosity of "about" 1 Pa-sec
refers to a viscosity from 0.95 to 1.05 Pa-sec, but also expressly
includes a viscosity of exactly 1 Pa-sec. Similarly, a perimeter
that is "substantially square" is intended to describe a geometric
shape having four lateral edges in which each lateral edge has a
length which is from 95% to 105% of the length of any other lateral
edge, but which also includes a geometric shape in which each
lateral edge has exactly the same length.
[0033] The term "elastic" as used herein mean materials having an
elongation of greater than or equal to 90% in either the cross
direction or the machine direction. The elastic porous layer
disclosed herein need not demonstrate recovery properties.
Accordingly, the term elastic as used herein is interchangeable
with the word extensible.
[0034] The term "substantially" with reference to a property or
characteristic means that the property or characteristic is
exhibited to a greater extent than the opposite of that property or
characteristic is exhibited. For example, a substrate that is
"substantially" transparent refers to a substrate that transmits
more radiation (e.g. visible light) than it fails to transmit (e.g.
absorbs and reflects). Thus, a substrate that transmits more than
50% of the visible light incident upon its surface is substantially
transparent, but a substrate that transmits 50% or less of the
visible light incident upon its surface is not substantially
transparent.
[0035] By using the term "overcoated" to describe the position of a
layer with respect to a substrate or other element of an article of
the present disclosure, we refer to the layer as being atop the
substrate or other element, but not necessarily contiguous to
either the substrate or the other element.
[0036] The term "homogeneous" means exhibiting only a single phase
of matter when observed at a macroscopic scale.
[0037] The term "(meth)acrylate" with respect to a monomer,
oligomer or means a vinyl-functional alkyl ester formed as the
reaction product of an alcohol with an acrylic or a methacrylic
acid.
[0038] The term "adjoining" with reference to a particular layer
means joined with or attached to another layer, in a position
wherein the two layers are either next to (i.e., adjacent to) and
directly contacting each other, or contiguous with each other but
not in direct contact (i.e., there are one or more additional
layers intervening between the layers).
[0039] The term "separated by" to describe the position of a layer
with respect to another layer and the substrate, or two other
layers, means that the described layer is between, but not
necessarily contiguous with, the other layer(s) and/or
substrate.
[0040] The term "(co)polymer" or "(co)polymeric" includes
homopolymers and copolymers, as well as homopolymers or copolymers
that may be formed in a miscible blend, e.g., by coextrusion or by
reaction, including, e.g., transesterification. The term
"copolymer" includes random, block, graft, and star copolymers.
[0041] The term "water vapor permeable" as used herein means an
article having a permeance of more than 1 perm (inch-pounds units)
according to ASTM E 96 Procedure A (Desiccant Method). Likewise,
water vapor impermeable refers to articles having a permeance of
less than 1 perm.
[0042] The term "discontinuous" as used herein means a coating
having an interrupted extension along a two dimensional surface.
For example, in some embodiments, an air and water barrier article
having a discontinuous coating of pressure sensitive adhesive does
not cover a major surface of a polymeric layer or a major surface
of a porous layer.
[0043] The term "perforated" as used herein means materials
allowing passage of liquids at ambient conditions.
[0044] The term "microporous" as used herein means a material that
is permeable to moisture vapor, but impermeable to liquid water at
55 cm of water pressure.
[0045] The term "air and water harrier" as used herein means
material that is designed and constructed to provide the principal
plane of air tightness through an environmental separator and that
has an air permeance rate no greater than 0.02 L per square meter
per second at a pressure difference of 75 Pa when tested in
accordance with ASTM E 2178-13 and provides acceptable barrier
performance with respect to water according to AATCC 127-2013. In
some embodiments, the air and water barrier is impermeable to
liquid water at 55 cm of water pressure.
[0046] The phrase "comprises at least one of" followed by a list
refers to comprising any one of the items in the list and any
combination of two or more items in the list. The phrase "at least
one of" followed by a list refers to any one of the items in the
list or any combination of two or more items in the list.
Air and Water Barrier Article
[0047] Referring now to FIG. 1, in some embodiments, presently
disclosed air and water barrier articles 100 include a polymeric
layer 130 that is disposed on and covers a first major surface 122
of an elastic porous layer 120.
[0048] In some embodiments, the presently disclosed air and water
barrier articles 100 include a layer of pressure sensitive adhesive
useful for adhering the air and water barrier 100 articles to
various surfaces. Referring now to FIG. 2, in some embodiments, the
presently disclosed air and water barrier articles 100 include an
adhesive layer 150 disposed on a major surface 124 of the elastic
porous layer 120 opposite the polymeric layer 130. Referring to
FIG. 3, in some embodiments, the presently disclosed air and water
barrier articles 100 include a first porous layer 160 disposed
between the polymeric layer 130 and the elastic porous layer 120.
In some embodiments, a second porous layer 170 disposed on a major
surface of the elastic porous layer 124 opposite the polymeric
layer 130, and an adhesive layer 150 disposed on a major surface
174 of the second porous layer 170 opposite the elastic porous
layer 120. In some embodiments, the pressure sensitive adhesive is
discontinuously disposed on at least one of the aforementioned
surfaces 124, 132, 174 in a random manner. In some embodiments, the
pressure sensitive adhesive is discontinuously disposed on at least
one of the aforementioned surfaces 124, 132, 174 in a patterned
manner. In some embodiments, the pressure sensitive adhesive covers
between 10% and 90% of the second major surface 124 of the elastic
porous layer 120, between 10% and 90% of the major surface 132 of
the polymeric layer 130, between 10% and 90% of the second major
surface 174 of the second porous layer 170, or between 10% and 90%
of both the second major surface 124 of the elastic porous layer
120 or the second major surface 174 of the second porous layer 170
and the major surface 132 of the polymeric layer 130. In some
embodiments, the pressure sensitive adhesive is a permeable
pressure sensitive adhesive that is continuously disposed on at
least one of a second major surface 124 of the elastic porous layer
120, a second major surface 174 of the second porous layer 170, a
major surface 132 of the polymeric layer 130, or combinations
thereof. In some embodiments, the pressure sensitive adhesive is
disposed only on one surface of the air and water barrier
article.
[0049] In some embodiments, the pressure sensitive adhesive layer
150 is discontinuously disposed on at least one of the outer the
first major surface 124 of the elastic porous layer 120 or the
first major surface 174 of the second porous layer 170. In some
embodiments, the pressure sensitive adhesive layer 150 is
discontinuously disposed on the first major surface 124 of the
elastic porous layer 120 or the first major surface 174 of the
second porous layer 170 in a random manner. In some embodiments,
the pressure sensitive adhesive is discontinuously disposed on the
first major surface 124 of the elastic porous layer 120 or the
first major surface 174 of the second porous layer 170 in a
patterned manner. In some embodiments, the pressure sensitive
adhesive covers 10% to 90% of the surface area of on the first
major surface 124 of the elastic porous layer 120 or the first
major surface 174 of the second porous layer 170. In some
embodiments, the pressure sensitive adhesive is a permeable
pressure sensitive adhesive that is continuously disposed on the
first major surface 124 of the elastic porous layer 120 or the
first major surface 174 of the second porous layer 170.
[0050] Referring now to FIG. 4A, any of the previously disclosed
embodiments of the presently disclosed air and water barrier
article can also include a microporous membrane 180 disposed on a
major surface 132 of the polymeric layer 130 opposite the elastic
porous layer 120. Referring now to FIG. 4B, any of the previously
disclosed embodiments of the sealing article can also include a
microporous membrane 180 disposed on a major surface 124 of the
elastic porous layer 120 opposite the polymeric layer 130. The
presently disclosed microporous membrane can comprise at least one
of stretched calcium carbonate filled polyolefin materials,
immiscible polymer materials having an extractable component, or
polyolefins.
[0051] In some embodiments, the presently disclosed air and water
barrier articles have an elongation of greater than or equal to 90%
in the cross direction, in some embodiments, greater than or equal
to 92% in the cross direction. In some embodiments, the air and
water barrier articles have an elongation of greater than or equal
to 90% in the machine direction, in some embodiments, greater than
or equal to 105% in the machine direction or greater than or equal
to 109% in the machine direction.
[0052] In some embodiments, air and water barrier articles
according to the present disclosure meet the requirements of
Modified Test 1 of ASTM D-1970/D-1970M-13, Modified Test 2 of ASTM
D-1970/D-1970M-13, Modified Test 3 of ASTM D-1970/D-1970M-13, or
combinations thereof. Meeting the requirements of Modified Test 1
of ASTM D-1970/D-1970M-13, Modified Test 2 of ASTM
D-1970/D-1970M-13, Modified Test 3 of ASTM D-1970/D-1970M-13, or
combinations thereof can depend on a variety of factors. In
general, polymeric layer comprising a polyoxyalkylene polymer
having at least one end group derived from an alkoxy silane can
cause the article to meet these requirements for nail sealability.
The presence of trialkoxy silane groups in the polymer precursor
and the presence of filler in the polymeric layer can also improve
the nail sealability of the air and water barrier article. In some
embodiments, self-sealing articles that meet the requirements of
Modified Test 1 of ASTM D-1970/D-1970M-13, Modified Test 2 of ASTM
D-1970/D-1970M-13, Modified Test 3 of ASTM D-1970/D-1970M-13 have a
polymeric layer including at least 5, 10, 15, 20, or 25 weight
percent filler, including any of the fillers described below. In
some embodiments, self-sealing articles that meet the requirements
of Modified Test 1 of ASTM D-1970/D-1970M-13, Modified Test 2 of
ASTM D-1970/D-1970M-13, Modified Test 3 of ASTM D-1970/D-1970M-13
include a polymeric layer having crosslinks derived from a
trialkoxy silane.
Elastic Porous Layer, First Porous Layer and Second Porous
Layer
[0053] The elastic porous layer, first porous layer, and second
porous layer may comprise a variety of suitable materials including
woven webs, non-woven webs, textiles, perforated plastic films, and
combinations thereof. The term "non-woven" refers to a material
having a structure of individual fibers or threads that are
interlaid but not in an identifiable manner such as in a knitted
fabric. Examples of non-woven webs include spunbond webs, spunlaced
webs, airlaid webs, meltblown web, and bonded carded webs. In some
embodiments, the substrate is a fibrous material (e.g., a woven,
nonwoven, or knit material). Useful porous layers may be made of
natural fibers (e.g., wood or cotton fibers), synthetic fibers
(e.g., thermoplastic fibers), or a combination of natural and
synthetic fibers. Examples of suitable materials for forming
thermoplastic fibers include polyolefins (e.g., polyethylene,
polypropylene, polybutylene, ethylene copolymers, propylene
copolymers, butylene copolymers, and copolymers and blends of these
polymers), polyesters, and polyamides. The fibers may also be
multi-component fibers, for example, having a core of one
thermoplastic material and a sheath of another thermoplastic
material. In some embodiments, the substrate comprises multiple
layers of nonwoven materials with, for example, at least one layer
of a meltblown nonwoven and at least one layer of a spunbonded
nonwoven, or any other suitable combination of nonwoven materials.
For example, the elastic porous layer, first porous layer, or
second porous layer may be a spunbond-meltblown-spunbond,
spunbond-spunbond, or spunbond-spunbond-spunbond multilayer
material.
[0054] In some embodiments, materials useful in the presently
disclosed elastic porous layer, first porous layer, or second
porous layer include perforated polymeric materials. In some
embodiments, perforated polymeric material is selected from
polyolefin, oriented polyolefin, polyester, oriented polyester,
multilayer films and combinations thereof. Examples of suitable
perforated materials, such as microperforated materials, are those
disclosed in WO 2011/081894 (Scheibner et al.), which is herein
incorporated by reference in its entirety. In some embodiments, the
presently disclosed elastic porous layer, first porous layer, or
second porous layer is a nonwoven comprising fibers selected from
polyester, polylactic acid, polyolefin, polyamide, rayon, and
combinations thereof.
[0055] In some embodiments, the elastic porous layer comprises at
least one of a plurality of elastomeric strands, elastic net,
elastic nonwoven material, elastic woven fabric, elastic knitted
fabric, elastic foam, or an elastic microperforated film. Examples
of useful materials for making any of these elastic materials
include thermoplastic elastomers such as ABA block copolymers,
polyurethane elastomers, polyolefin elastomers (e.g., metallocene
polyolefin elastomers), polyamide elastomers, ethylene vinyl
acetate elastomers, and polyester elastomers. An ABA block
copolymer elastomer generally is one where the A blocks are
polystyrenic, and the B blocks are conjugated dienes (e.g., lower
alkylene dienes). The A block is generally formed predominantly of
substituted (e.g, alkylated) or unsubstituted styrenic moieties
(e.g., polystyrene, poly(alphamethylstyrene), or
poly(t-butylstyrene)), having an average molecular weight from
about 4,000 to 50,000 grams per mole. The B block(s) is generally
formed predominantly of conjugated dienes (e.g., isoprene,
1,3-butadiene, or ethylene-butylene monomers), which may be
substituted or unsubstituted, and has an average molecular weight
from about 5,000 to 500,000 grams per mole. The A and B blocks may
be configured, for example, in linear, radial, or star
configurations. An ABA block copolymer may contain multiple A
and/or B blocks, which blocks may be made from the same or
different monomers. A typical block copolymer is a linear ABA block
copolymer, where the A blocks may be the same or different, or a
block copolymer having more than three blocks, predominantly
terminating with A blocks. Multi-block copolymers may contain, for
example, a certain proportion of AB diblock copolymer, which tends
to form a more tacky elastomeric film segment. In some embodiments,
the elastic porous layer useful for practicing the present
disclosure is made from a variety of useful materials (e.g.,
polypropylene, polypropylene-polyethylene copolymers, and
thermoplastic polyurethanes). In some embodiments, the elastic
porous layer is made, for example, from multi-component (e.g.,
bi-component such as core-sheath) fibers.
[0056] Several materials useful for making the elastic porous layer
are commercially available, for example, polyolefins from
ExxonMobil, Houston, Tex., under the trade designation "VISTAMAXX"
and thermoplastic polyurethane elastomers from Huntsman, The
Woodlands, Tex., under the trade designation "IROGRAN". In some
embodiments, the elastic porous layer comprises a marnix nonwoven.
In some embodiments, the elastic porous layer comprises a spunbond
nonwoven available from Idemitsu Kosan Co., Ltd., Tokyo, Japan,
under the trade designation "STRAFLEX".
[0057] In some embodiments, the elastic porous layer, first porous
layer, or second porous layer comprises blown microfibers. In some
embodiments, the elastic porous layer, first porous layer, or
second porous layer includes at least one extruded netting or
scrims. In some embodiments, the elastic porous layer, first porous
layer, or second porous layer is a woven material.
[0058] In some embodiments, the elastic porous layer, first porous
layer, or second porous layer is microporous membrane. Suitable
microporous membranes include a thermally induced phase separated
porous membrane as described in U.S. Pat. No. 5,120,594
(Mrozinski). Such membranes are commercially available under the
trade designation "PROPORE" from 3M, St. Paul, Minn. Another
suitable microporous membranes is a stretched calcium carbonate
filled polyolefin film as described in U.S. Pat. No. 4,923,650
(Antoon). Such membranes are commercially available under the trade
designation "MICROPRO" from Clopay Plastics, Mason, Ohio. Suitable
microporous membranes can further include spunbonded or fibrous
bonded polyolefin as described in U.S. Pat. No. 3,532,589 (David)
and U.S. Pat. No. 5,972,147 (Janis). In some instances, the
polyolefins (e.g., polyethylene and polypropylene) are cast,
annealed, and then stretched. One suitable microporous membrane is
commercially available under the trade designation "TYVEK" from
E.I. Du Pont deNemours Corp., Wilmington, Del. Other suitable
microporous membranes include oriented polymeric films as described
in U.S. Pat. No. 5,317,035 (Jacoby et al.), and which comprise
ethylene-propylene block copolymers. Such membranes are
commercially available under the trade designation "APTRA films"
from BP-Amoco Corp., Atlanta, Ga. Suitable microporous membranes
can be formed from immiscible polymer materials or polymer
materials that have an extractable component, such as solvent.
These materials are stretched after casting.
[0059] In some embodiments, the elastic porous layer has a moisture
vapor transmission rate of at least 1 perm, at least 5 perms, or at
least 10 perms.
[0060] In some embodiments, the elastic porous layer can dissipate
water in the plane of the elastic porous layer. This is shown in
Table 7, below. Such water dissipation can provide a mechanism for
passing at least one of the nail sealability tests by removing the
water from the nail sites. In some embodiments, the elastic porous
layer has a water strike through time of up to 400, 300, or 250
seconds as measured according to the test method in the examples,
below.
Polymeric Layer
[0061] A variety of polymeric materials are useful for covering and
in some embodiments at least partially impregnating and/or
encapsulating the porous layer described above in any of its
embodiments to make the air and water barrier article according to
the present disclosure. In some embodiments, the polymeric material
is a polyoxyalkylene polymer having at least one end group derived
from an alkoxy silane. The polyoxyalkylene polymer may be silyl
terminated. In some embodiments, the polyoxyalkylene polymer
further comprises at least one silyl modified branched group.
[0062] A production method of a polyoxyalkylene polymer having a
reactive silicon group may include those proposed in Japanese
Kokoku Publication S45-36319, Japanese Kokoku Publication
S46-12154, Japanese Kokai Publication S50-156599, Japanese Kokai
Publication S54-6096, Japanese Kokai Publication S55-13767,
Japanese Kokai Publication S55-13468, Japanese Kokai Publication
S57-164123, Japanese Kokoku Publication H3-2450, U.S. Pat. No.
3,632,557, U.S. Pat. No. 4,345,053, U.S. Pat. No. 4,366,307, and
U.S. Pat. No. 4,960,844. Also, useful polymers for the air and
water barrier articles according to the present disclosure include
polyoxyalkylene polymers having a number average molecular weight
of 6,000 or higher and a Mw/Mn ratio of 1.6 or lower and thus
having high molecular weight and narrow molecular weight
distribution as disclosed in Japanese Kokai Publication S61-197631,
Japanese Kokai Publication S61-215622, Japanese Kokai Publication
S61-215623, Japanese Kokai Publication S61-218632, Japanese Kokai
Publication H3-72527, Japanese Kokai Publication H3-47825, and
Japanese Kokai Publication H8-231707.
[0063] In some embodiments, the main chain of the polyoxyalkylene
polymer may contain other functional groups such as a urethane
bond. The aforementioned urethane bond component is not
particularly limited and may include a segment (hereinafter, also
referred to as an amido segment) produced by reaction of an
isocyanato group and an active hydrogen group.
[0064] The amido segment can be represented by the following
formula:
--NR.sup.5--C(O)--
[0065] (wherein R.sup.5 represents a hydrogen atom or a monovalent
organic group, desirably a substituted or unsubstituted monovalent
C.sub.1-20 hydrocarbon group, and more desirably a substituted or
unsubstituted monovalent C.sub.1-8 hydrocarbon group).
[0066] The aforementioned amido segment may be part of a urethane
group produced, for example, by reaction of an isocyanato group and
a hydroxy group; a urea group produced by reaction of an isocyanato
group and an amino group; and a thiourethane group produced by
reaction of an isocyanato group and a mercapto group. Also, in the
present disclosure, groups produced by reaction of an active
hydrogen in the aforementioned urethane group, urea group, and
thiourethane group with another isocyanato group also include a
segment represented by the formula
--NR.sup.5--C(O)--.
[0067] Examples of methods for industrially producing a
polyoxyalkylene polymer having an amido segment and a reactive
silicon group include those disclosed in Japanese Kokoku
Publication S46-12154 (U.S. Pat. No. 3,632,557), Japanese Kokai
Publications S58-109529 (U.S. Pat. No. 4,374,237), S62-13430 (U.S.
Pat. No. 4,645,816), H8-53528 (EP 0676403), and H10-204144 (EP
0831108), Japanese Kohyo Publication 2003-508561 (U.S. Pat. No.
6,197,912), Japanese Kokai Publications H6-211879 (U.S. Pat. No.
5,364,955), H10-53637 (U.S. Pat. No. 5,756,751), H11-100427,
2000-169544, 2000-169545 and 2002-212415, Japanese Patent No.
3,313,360, U.S. Pat. Nos. 4,067,844 and 3,711,445, Japanese Kokai
Publications 2001-323040, H11-279249 (U.S. Pat. No. 5,990,257),
2000-119365 (U.S. Pat. No. 6,046,270), S58-29818 (U.S. Pat. No.
4,345,053), H3-47825 (U.S. Pat. No. 5,068,304), H11-60724,
2002-155145, and 2002-249538, WO03/018658, WO03/059981, and
Japanese Kokai Publication H6-211879 (U.S. Pat. No. 5,364,955),
H10-53637 (U.S. Pat. No. 5,756,751), H10-204144 (EP0831108),
2000-169544, 2000-169545, and 2000-119365 (U.S. Pat. No.
6,046,270).
[0068] A (meth) acrylic ester polymer having a reactive silicon
group may be added to the polyoxyalkylene polymer having a reactive
silicon group, if desired. Various (meth) acrylic ester monomers
may be useful for providing the main chain of the (meth) acrylic
ester polymer. Examples of useful (meth) acrylic ester monomers
include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl
(meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth)
acrylate, isobutyl (meth) acrylate, t-butyl (meth) acrylate,
n-pentyl (meth) acrylate, n-hexyl (meth) acrylate, cyclohexyl
(meth) acrylate, n-heptyl (meth) acrylate, n-octyl (meth) acrylate,
2-ethylhexyl (meth) acrylate, nonyl (meth) acrylate, decyl (meth)
acrylate, dodecyl (meth) acrylate, phenyl (meth) acrylate, tolyl
(meth) acrylate, benzyl (meth) acrylate, 2-methoxyethyl (meth)
acrylate, 3-methoxybutyl (meth) acrylate, 2-hydroxyethyl (meth)
acrylate, hydroxypropyl (meth) acrylate, stearyl (meth) acrylate,
glycidyl (meth) acrylate, 2-aminoethyl (meth) acrylate,
gamma-(methacryloyloxypropyl) trimethoxysilane,
gamma-(methacryloyloxypropyl) dimethoxymethylsilane,
methacryloyloxymethyltrimethoxysilane,
methacryloyloxymethyltriethoxysilane;
methacryloyloxymethyldimethoxymethylsilane;
methacryloyloxymethyldiethoxymethylsilane, ethylene oxide adduct of
(meth) acrylic acid, trifluoromethylmethyl (meth) acrylate,
2-trifluoromethylethyl (meth) acrylate, 2-perfluoroethylethyl
(meth) acrylate, 2-perfluoroethyl-2-perfluorobutylethyl (meth)
acrylate, perfluoroethyl (meth) acrylate, trifluoromethyl (meth)
acrylate, bis (trifluoromethyl) methyl (meth) acrylate,
2-trifluoromethyl-2-perfluoroethylethyl (meth) acrylate,
2-perfluorohexylethyl (meth) acrylate, 2-perfluorodecylethyl (meth)
acrylate, and 2-perfluorohexadecylethyl (meth) acrylate.
[0069] With respect to the (meth) acrylic ester polymer, vinyl
monomers can be copolymerized together with a (meth) acrylic ester
monomer. Examples of suitable vinyl monomers include styrene
monomers such as styrene, vinyltoluene, alpha-methylstyrene,
chlorostyrene, styrenesulfonic acid and its salts;
fluorine-containing vinyl monomers such as perfluoroethylene,
perfluoropropylene, and vinylidene fluoride; silicon-containing
vinyl monomers such as vinyltrimethoxysilane and
vinyltriethoxysilane; maleic anhydride, maleic acid, and monoalkyl
and dialkyl esters of maleic acid; fumaric acid, and monoalkyl and
dialkyl esters of fumaric acid; maleimide monomers such as
maleimide; methylmaleimide; ethylmaleimide, propylmaleimide,
butylmaleimide, hexylmaleimide, octylmaleimide, dodecylmaleimide,
stearylmaleimide, phenylmaleimide, and cyclohexylmaleimide; nitrile
group-containing vinyl monomers such as acrylonitrile and
methacrylonitrile; amido group-containing vinyl monomers such as
acrylamide and methacrylamide; vinyl esters such as vinyl acetate;
vinyl propionate, vinyl pivalate, vinyl benzoate, and vinyl
cinnamate; alkenes such as ethylene and propylene; conjugated
dienes such as butadiene and isoprene; and vinyl chloride,
vinylidene chloride, allyl chloride; and allyl alcohol. Any of
these monomers may be used alone or any combination of them may be
copolymerized withthe (meth) acrylic acid monomer. In some
embodiments, polymers comprising a styrene monomer and/or a
(meth)acrylic acid monomer are desirable. In the above
descriptions, (meth) acrylic acid means acrylic acid and/or
methacrylic acid.
[0070] The (meth) acrylic ester polymer can be prepared, for
example, by a conventionally known method. For example, a "living
radical polymerization" method can be conveniently employed in
order to obtain a (meth) acrylic ester polymer having narrow
molecular weight distribution and low viscosity and having a
reactive silicon group at a molecular chain end at a high ratio. An
"atom transfer radical polymerization" method is a living radical
polymerization method useful for polymerizing a (meth) acrylic
ester monomer using, for example, an organic halide or a
halogenated sulfonyl compound as an initiator and a transition
metal complex as a catalyst. An atom transfer radical
polymerization method advantageously has a wide range of options
for the initiator and the catalyst. Because a halogen is located at
a molecular chain end, which is relatively advantageous for a
functional group conversion reaction, the atom transfer radical
polymerization method is useful as a production method of the
(meth) acrylic ester polymer having a specified functional group.
Examples of the atom transfer radical polymerization method include
the method disclosed in Krzysztof Matyjaszewski et al., J. Am.
Chem. Soc, vol. 117, p. 5614 (1995) and the method disclosed in
Japanese Kokai Publication H9-272714.
[0071] Other examples of a production method of the (meth) acrylic
ester polymer having a reactive silicon group are production
methods employing free radical polymerization methods using chain
transfer agents and disclosed in Japanese Kokoku Publication
H3-14068, Japanese Kokoku Publication H4-55444, and Japanese Kokai
Publication H6-211922. The above-mentioned (meth) acrylic ester
polymers having a reactive silicon group may be used alone or two
or more kinds of them may be used in combination.
[0072] Examples of methods for producing an organic polymer
involving blending a polyoxyalkylene polymer having a reactive
silicon group with a (meth) acrylic ester polymer having a reactive
silicon group include those disclosed in Japanese Kokai Publication
S59-122541, S63-11264, H6-172631, and H11-116763. Further, a
production method for a polyoxyalkylene polymer obtained by
blending the (meth) acrylic ester polymer having a reactive silicon
group may also include a method of polymerizing a (meth) acrylic
ester monomer in the presence of a polyoxyalkylene polymer having a
reactive silicon group. Examples of these methods include those
disclosed in Japanese Kokai Publication 559-78223, Japanese Kokai
Publication S59-168014, Japanese Kokai Publication S60-228516, and
Japanese Kokai Publication 560-228517.
[0073] Some of the silyl terminated polymers useful in the air and
water barrier articles according to the present disclosure are
commercially available, for example, from Kaneka Corporation under
the trade designations "KANEKA MS POLYMER" and "KANEKA SILYL", and
from Union Carbide Specialty Chemicals Division under the trade
designations "SILMOD-SAT10", "SILMOD SAT30", "SILMOD SAT 200",
"SILMOD S203", "SILMOD S303", "SILMOD 20A", to name several, which
were obtained from Union Carbide Company. It has been reported that
resins available under the trade designation "SILMOD" have
substantially the same chemistries as some resins available under
the trade designations "MS" and "SILYL" from Kanegafuchi Kagaku
Kogyo Kabushiki Kaisha, Osaka Japan. For example, the material
available under trade designation "SILMOD S203" corresponds to the
material available under trade designation "MS S203", the material
available under trade designation "SILMOD S303" corresponds to the
material available under trade designation "MS S303", and the
material available under trade designation "SILMOD 20A" corresponds
to the material available under trade designation "MS 20A". In
further examples, the composition available under the trade
designation "SILMOD SAT10" corresponds to the composition available
under the trade designation "SILYL SAT10", the composition
available under the trade designation "SILMOD SAT30" corresponds to
the composition available under the trade designation "SILYL
SAT30", and the composition available under the trade designation
"SILMOD 200" corresponds to the composition available under the
trade designation "SILYL 200".
[0074] Materials useful in the presently disclosed polymeric layer
include solid materials and foam materials. In some embodiments,
the foam material includes closed cell foams.
[0075] Polymeric materials useful for the air and water barrier
articles of the present disclosure may optionally include various
additives such as dehydrating agents, rheology additives,
compatibilizers, tackifiers, physical property modifiers,
photocurable substances, oxygen-curable substances, storage
stability improving agents, fillers, epoxy resins, epoxy resin
curing agents antioxidants, adhesion promoters, ultraviolet
absorbers, metal deactivators, antiozonants, antioxidants, light
stabilizers, lubricants, amine type radical chain inhibitors,
phosphorus-containing peroxide decomposers, lubricants, pigments,
foaming agents, solvents, flame retardants, antifungal agents,
blowing agents, and antistatic agents, each in an adequate amount.
These additives may be added singly to the polymeric material or
two or more thereof may be added in combination to the polymeric
material. Specific examples of these additives are disclosed in
publications such as Japanese Kokoku Publications H4-69659 and
H7-108928, and Japanese Kokai Publications S63-254149, S64-22904,
2001-72854, and 2008-303650.
[0076] In the polymeric layers useful for the air and water barrier
articles of the present disclosure, at least one of UV stabilizers
or antioxidants may be present in an amount from 0 to 5 parts per
100 parts of the silyl terminated polymer. These materials improve
heat stability and UV resistance. Some useful UV stabilizers and
antioxidants are commercially available, for example, those
available under the trade designations "TINUVIN 770", "TINUVIN
327", "TINUVIN 1130" and "TINUVIN 292" from BASF, Florham Park,
N.J.
[0077] In some embodiments, the polymeric layer useful for
practicing the present disclosure includes at least 0.1 wt. %, in
some embodiments at least 0.5 wt. % of one or more water
scavengers, and at most 5 wt. %, in some embodiments at most 2 wt %
of one or more water scavengers. Examples of suitable water
scavengers include silanes such as vinyltrimethoxysilane,
vinyltriethoxysilane, vinylmethyldimethoxysilane,
O-methylcarbamatomethyl-methyldimethoxysilane,
O-methylcarbamatomethyl-trimethoxysilane,
O-ethylcarbamatomethyl-methyldiethoxysilane,
O-ethyl-carbamatomethyl-triethoxysilane,
3-methacryloyloxypropyl-trimethoxysilane,
methacryloyloxymethyltrimethoxysilane, me
thacryloyloxymethylmethyldimethoxysilane, methacryloyloxymethyltrie
thoxysilane, methacryloxymethylmethyl-diethoxysilane,
3-acryloxyoylpropyl-trimethoxysilane,
acryloyloxymethyltrimethoxysilane,
acryloyloxymethylmethyldimethoxysilane, acrylmethyltriethoxysilane,
acryloyloxymethylmethyldiethoxysilane, alkylalkoxysilanes in
general, and further functionalized organosilanes and other
aminosilanes, which are also described below as adhesion
promoters.
[0078] In some embodiments, the polymeric materials useful for
practicing the present disclosure include at least 0.1 wt %, in
some embodiments, at least 0.5 wt %, of one or more adhesion
promoters. In some embodiments, the presently disclosed polymeric
materials include at most 5 wt %, in some embodiments, at most 2 wt
%, of one or more adhesion promoters. Useful adhesion promoters
include those available under the trade designations "A1120",
"A187", and "A189" from OSI and "Z9020" from Dow Chemical. Amino
silanes can be used as adhesion promoters. Examples of amino silane
useful as adhesion promoters include
gamma-aminopropyltrimethoxysilane,
gamma-aminopropyltriethoxysilane,
gamma-aminopropyltriisopropoxysilane,
gamma-aminopropylmethyldimethoxysilane,
gamma-aminopropylmethyldiethoxysilane,
gamma-(2-aminoethyl)aminopropyltrimethoxysilane,
gamma-(2-aminoethyl)aminopropylmethyldimethoxysilane,
gamma-(2-aminoethyl)aminopropyltriethoxysilane,
gamma-(2-aminoethyl)aminopropylmethyldiethoxysilane,
gamma-(2-aminoethyl)aminopropyltriisopropoxysilane,
gamma-(6-aminohexyl)aminopropyltrimethoxysilane,
3-(N-ethylamino)-2-methylpropyltrimethoxysilane,
2-aminoethylaminomethyltrimethoxysilane,
N-cyclohexylaminomethyltriethoxysilane,
N-cyclohexylaminomethyldiethoxymethylsilane,
gamma-ureidopropyltrimethoxysilane,
gamma-ureidopropyltriethoxysilane,
N-phenyl-gamma-aminopropyltrimethoxysilane,
N-phenylaminomethyltrimethoxysilane,
N-benzyl-gamma-aminopropyltrimethoxysilane,
N-vinylbenzyl-gamma-aminopropyltriethoxysilane,
N,N'-bis[3-trimethoxysilyl]propyllethylenediamine,
N-cyclohexylaminomethyltrimethoxysilane,
N-cyclohexylaminomethyldimethoxymethylsilane, and
N-phenylaminomethyltrimethoxysilane.
[0079] In some embodiments, the polymeric materials useful for
practicing the present disclosure may comprise one or more
catalysts. The catalyst may be present in the polymeric material in
an amount of from about 0.05 wt % to about 5 wt %, in some
embodiments from about 0.1 wt % to about 2 wt %, and in some
embodiments, from about 0.1 wt % to about 1 wt %. Useful catalysts
include organometallic compounds which are known as silanol
condensation catalysts. The silanol condensation catalyst may be
used in an amount of from about 0.01 to about 20 parts by weight
per 100 parts by weight of the silyl-terminated polymer, in some
embodiments, from about 0.1 to about 10 parts by weight per 100
parts by weight of the silyl-terminated polymer. Examples of
suitable silanol condensation catalysts include titanate esters
such as tetrabutyl titanate and tetrapropyl titanate; organotin
compounds such as dibutyltin dilaurate, dibuytltin maleate,
dibutyltin diacetate, stannous octylate, stannous napthenate,
reaction products from dibutyltin oxide and phthalate esters, and
dibutyltin diacetylacetonate; organoaluminum compounds such as
aluminum trisacetylacetonate, aluminum tris(ethylacetoacetate) and
diisopropocyaluminum ethyl acetoacetate; reaction products from
bismuth salts and organic carboxylic acids, such as bismuth
tris(2-ethylhexonate) and bismuth tris(neodecanoate); chelate
compounds such as zirconium tetra-acetylacetonate and titanium
tetra-acetylactonate; organolead compounds such as lead octylate;
organovanadium compounds; amines such as butylamine, octylamine,
dibutylamine, monoethanolamine, oleylamine, cyclohexylamine,
benzylamine, diethylaminopropylamine, xylenediamine,
triethylenediamine, guanidine, diphenylguanidine,
2,4,6-tris(dimethylaminomethyl)phenol, morpholine,
N-methylmorpholine, 2-ethyl-4-methylimidazole with carboxylic or
other acids; low-molecular-weight polyamide resins derived from
excess polyamines and polybasics acids; and reaction products from
excess polyamines and epoxy compounds. Any of these may be used
individually or in combination.
[0080] In some embodiments, polymeric materials useful for
practicing the present disclosure comprise one or more pigments or
fillers. Useful fillers are typically solids that are non-reactive
with the other components of the polymeric material, porous
material, and coating compositions. Useful fillers include, for
example, clay, talc, dye particles, pigments and colorants (for
example, titanium dioxide and carbon black), glass beads, metal
oxide particles, silica particles, ceramic microspheres, hollow
polymeric microspheres (such as those available under the trade
designation "EXPANCEL 551 DE" from Akzo Nobel, Duluth, Ga.), hollow
glass microspheres (such as those available under the trade
designation "K37" from 3M Co., St Paul, Minn.), carbonates, metal
oxides, silicates (e.g. talc, asbestos, clays, mica), sulfates,
silicon dioxide and aluminum trihydrate. Some specific examples
include ground or light calcium carbonate (with or without a
surface-treatment such as a fatty acid, resin acid, cationic
surfactant, or anionic surfactant); magnesium carbonate; talc;
sulfates such as barium sulfate; alumina; metals in powder form
(e.g., aluminum, zinc and iron); bentonite; kaolin clay; quartz
powder; and combinations of two or more of these.
[0081] Examples of useful organic pigments include halogenated
copper phthalocyanines, aniline blacks, anthraquinone blacks,
benzimidazolones, azo condensations, arylamides, diarylides, disazo
condensations, isoindolinones, isoindolines, quinophthalones,
anthrapyrimidines, flavanthrones, pyrazolone oranges, perinone
oranges, beta-naphthols, arylamides, quinacridones, perylenes,
anthraquinones, dibromanthrones, pyranthrones,
diketopyrrolo-pyrrole pigments (DPP), dioxazine violets, copper and
copper-free phthalocyanines, and indanthrones.
[0082] Examples of useful inorganic pigments include titanium
dioxide, zinc oxide, zinc sulphide, lithopone, antimony oxide,
barium sulfate, carbon black, graphite, black iron oxide, black
micaceous iron oxide, brown iron oxides, metal complex browns, lead
chromate, cadmium yellow, yellow oxides, bismuth vanadate, lead
chromate, lead molybdate, cadmium red, red iron oxide, Prussian
blue, ultramarine, cobalt blue, chrome green (Brunswick green),
chromium oxide, hydrated chromium oxide, organic metal complexes,
and laked dye pigments.
[0083] The filler can also comprise conductive particles (see, for
example, U.S. Patent Application Pub. No. 2003/0051807, which is
incorporated herein by reference) such as carbon particles or metal
particles of silver, copper, nickel, gold, tin, zinc, platinum,
palladium, iron, tungsten, molybdenum, solder or the like, or
particles prepared by covering the surface of these particles with
a conductive coating of a metal or the like. It is also possible to
use non-conductive particles of a polymer such as polyethylene,
polystyrene, phenol resin, epoxy resin, acryl resin or
benzoguanamine resin, or glass beads, silica, graphite or a
ceramic, whose surfaces have been covered with a conductive coating
of a metal.
[0084] In some embodiments, the polymeric material includes
inorganic solids such as talc, titanium dioxide, silica, zirconia,
calcium carbonate, calcium magnesium carbonate, glass or ceramic
microspheres, or combinations thereof. In some embodiments, the
polymeric material includes at least one of titanium dioxide or
calcium carbonate.
[0085] In some embodiments, the polymeric material useful for
practicing the present disclosure comprises a plasticizer. In some
of these embodiments, the plasticizer does not contain any groups
reactive toward silane/alkoxysilane. Examples of suitable
plasticizers for the polymeric material include which polyethers,
polyether esters, esters of organic carboxylic acids or anhydrides
thereof, such as phthalates (e.g., dialkyl phthalates such as
di-(2-ethyl-hexyl)-pththalates, dibutyl phthalate, diethyl
phthalate, dioctyl phthalate, butyl octyl phthalate, dicyclohexyl
phthalate, butyl benzyl phthalate, dioctyl phthalate, diisononyl
phthalate, and diisodecyl phthalate); adipates (e.g.,
di-(2-ethylhexyl)adipate, diisooctyl adipate, octyl decyladipate;
and dioctyl adipate); alkyl azelates (e.g., di(2-ethylhexyl)azelate
and di-(2-ethylbutyl)azelate); and dialkyl sebacates (e.g., dibutyl
sebacate, dioctylsebacate, and diisooctyl sebacate). Other suitable
plasticizers include phosphates such as triaryl phosphates (e.g.,
tricresyl phosphate, triphenyl phosphate, cresyl(liphenyl
phosphate); trialkyl phosphates (e.g., trioctyl phosphate and
tributyl phosphate); alkoxyalkyl phosphates (e.g., trisbutoxyethyl
phosphate); and alkyl aryl phosphates (e.g., octyldiphenyl
phosphate); citrates such as acetyl tri-n-butyl citrate, acetyl
triethyl citrate, monoisopropyl citrate, triethyl citrate, mono-,
di-, and tri-stearyl citrate; triacetin; p-tert-butyl; n-octyl
benzoate; 2-ethylhexyl benzoate; isooctyl benzoate; n-nonyl
benzoate; n-decyl benzoate; isodecyl benzoate; 2-propylheptyl
benzoate; n-undecyl benzoate; isoundecyl benzoate; n-dodecyl
benzoate; isododecyl benzoate; isotridecyl benzoate; n-tridecyl
benzoate; triisononyl trimellitate; C.sub.13-rich
C.sub.11-C.sub.14-alkyl benzoates, and combinations thereof. In
some embodiments, plasticizers useful for practicing the present
disclosure include esters, such as triethylene glycol bis
(2-ethylhexanoate) commercially available under the trade
designation "Eastman TEG-EH" from Eastman. In some embodiments, at
least one of diethylene glycol monobenzoate, diethylene glycol
dibenzoate, propylene glycol monobenzoate, propylene glycol
dibenzoate, polypropylene glycol monobenzoate, polypropylene glycol
dibenzoate can be used individually or in combination with any of
the aforementioned plasticizers.
[0086] The amount of plasticizer employed, if one is employed, will
depend on the nature of the polymeric resin and the
plasticizer.
[0087] The polymeric material useful for practicing the present
disclosure may comprise one or more organic solvents. Examples of
suitable solvents include non-reactive compounds which may be
aliphatic, aromatic, or araliphatic. Examples of suitable solvents
include methoxypropyl acetate, methoxyethyl acetate, ethylene
glycol diacetate, propylene glycol diacetate, glyme, diglyme,
dioxane, tetrahydrofuran, dioxolane, tert-butyl methyl ether, ethyl
acetate, butyl acetate, chloroform, methylene chloride,
chlorobenzene, o-dichlorobenzene, anisole, 1,2-dimethoxybenzene,
phenyl acetate, N-methyl-2-pyrrolidone, dimethylformamide,
N,N-dimethylacetamide, dimethyl sulphoxide, acetonitrile,
phenoxyethyl acetate, and combinations of two or more of these. In
some embodiments, the solvent comprises at least one of
methoxypropyl acetate, acetone, 2-butanone, xylene, toluene,
cyclohexanone, 4-methyl-2-pentanone, 1-methoxyprop-2-yl acetate,
ethylene glycol monomethyl ether, 3-methoxy-n-butyl acetate, white
spirit, more highly substituted aromatics such as thosecommercially
available, for example, under the trade designations "NAPTHA",
"SOLVESSO", "ISOPAR", "NAPPAR" from Deutsche EXXON CHEMICAL GmbH,
Cologne, DE; "SHELLSOL" from Deutsche Shell Chemie GmbH, Eschborn,
DE; methyl n-amyl ketone ("MAK") and "AROMATIC 100" "AROMATIC 150"
from ExxonMobile Chemical; xylene, methyl isobutyl ketone ("MIBK"),
and ethyl 3-ethoxypropionate from Eastman Chemical Company.
[0088] Additional compositions useful for the polymeric material
useful for practicing the present disclosure can be found in Int.
Pat. Appl. Pub. Nos. WO 2015/126931 (Seabaugh et al.) and WO
2015/183354 (Widenbrant et al.), the examples of which are
incorporated herein by reference.
Pressure Sensitive Adhesive
[0089] In some embodiments, the air and water barrier articles
according to the present disclosure are self-adhering, comprising
an adhesive layer, in some embodiments, a pressure sensitive
adhesive (PSA) material. PSAs are well known to those of ordinary
skill in the art to possess properties including the following: (1)
aggressive and permanent tack, (2) adherence with no more than
finger pressure, (3) sufficient ability to hold onto an adherend,
and (4) sufficient cohesive strength to be cleanly removable from
the adherend. Materials that have been found to function well as
PSAs are polymers designed and formulated to exhibit the requisite
viscoelastic properties resulting in a desired balance of tack,
peel adhesion, and shear holding power.
[0090] A variety of pressure sensitive adhesives are useful for
adhering air and water barrier articles to architectural structures
(e.g., buildings) and building components, for example. These
include both water vapor permeable and water vapor impermeable
pressure sensitive adhesives. An example of the latter is a rubber
modified asphalt (bitumen) pressure sensitive adhesive or a
synthetic rubber pressure sensitive adhesive. Such pressure
sensitive adhesives are well known in the art and understood to be
water vapor impermeable. Further examples of suitable PSAs include
natural rubber-, acrylic-, block copolymer-, silicone-,
polyisobutylene-, polyvinyl ether-, polybutadiene-, or and
urea-based pressure sensitive adhesive and combinations thereof.
These PSAs can be prepared, for example, as described in Adhesion
and Adhesives Technology, Alphonsus V. Pocius, Hanser/Gardner
Publications, Inc., Cincinnati, Ohio, 1997, pages 216 to 223,
Handbook of Pressure Sensitive Adhesive Technology, Donatas Satas
(Ed.), 2nd Edition, Van Nostrand Reinhold, New York, N.Y., 1989,
Chapter 15, and U.S. Pat. No. Re 24,906 (Ulrich).
[0091] In some embodiments, the adhesive is selected to be a
solventless or hot melt adhesive. In some embodiments, solvent
based adhesives or water based adhesives may be used. Examples of
suitable adhesives include radiation-cured (e.g., ultraviolet (UV)
radiation or electron-beam cured (co)polymers resulting from
polymerizable monomers or oligomers) may be used. Suitable hot melt
adhesives may contain (co)polymers such as butyl rubber,
styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS),
styrene butadiene (SB), styrene-ethylene-butadiene-styrene (SEBS),
and ethylene/vinylacetate (EVA). Tackifying resins, which generally
refer to materials that are compatible with the elastomer and have
a number average molecular weight of up to 10,000 grams per mole,
are typically added to these elastomers. Useful tackifying resins
can have a softening point of at least 70.degree. C. as determined
using a ring and ball apparatus and a glass transition temperature
of at least -30.degree. C. as measured by differential scanning
calorimetry. In some embodiments, the tackifying resin comprises at
least one of rosin, a polyterpene (e.g., those based on
.alpha.-pinene, .beta.-pinene, or limonene), an aliphatic
hydrocarbon resin (e.g., those based on cis- or trans-piperylene,
isoprene, 2-methyl-but-2-ene, cyclopentadiene, dicyclopentadiene,
or combinations thereof), an aromatic resin (e.g. those based on
styrene, .alpha.-methyl styrene, methyl indene, indene, coumarone,
or combinations thereof), or a mixed aliphatic-aromatic hydrocarbon
resin. Any of these tackifying resins may be hydrogenated (e.g.,
partially or completely). Natural and petroleum waxes, oil, and
bitumen may be useful as additives to the pressure sensitive
adhesive composition.
[0092] In some embodiments, PSAs compositions that are useful in
the roll and method according to the present disclosure are acrylic
PSAs. As used herein, the term "acrylic" or "acrylate" includes
compounds having at least one of acrylic or methacrylic groups.
Useful acrylic PSAs can be made, for example, by combining at least
two different monomers including certain of the second monomers
described above. Examples of suitable second monomers include
2-methylbutyl acrylate, 2-ethylhexyl acrylate, isooctyl acrylate,
lauryl acrylate, n-decyl acrylate, 4-methyl-2-pentyl acrylate,
isoamyl acrylate, sec-butyl acrylate, isononyl acrylate, and
methacrylates of the foregoing acrylates. Examples of suitable
additional monomers useful for preparing acrylic PSAs include a
(meth)acrylic acid (e.g., acrylic acid, methacrylic acid, itaconic
acid, maleic acid, and fumaric acid), a (meth)acrylamide (e.g.,
acrylamide, methacrylamide, N-ethyl acrylamide, N-hydroxyethyl
acrylamide, N-octyl acrylamide, N-t-butyl acrylamide, N,N-dimethyl
acrylamide, N,N-diethyl acrylamide, N-ethyl-N-dihydroxyethyl
acrylamide, and methacrylamides of the foregoing acrylamides), a
(meth)acrylate (e.g., 2-hydroxyethyl acrylate or methacrylate,
cyclohexyl acrylate, t-butyl acrylate, isobornyl acrylate, and
methacrylates of the foregoing acrylates), N-vinyl pyrrolidone,
N-vinyl caprolactam, an alpha-olefin, a vinyl ether, an allyl
ether, a styrenic monomer, or a maleate. In some embodiments, the
PSA in the composition according to the present disclosure includes
a pendent carboxylic acid group incorporated into the PSA by
including, for example, acrylic acid, methacrylic acid, itaconic
acid, maleic acid, or fumaric acid in the preparation of the
PSA.
[0093] Acrylic PSAs may also be made by including cross-linking
agents in the formulation. Examples of cross-linking agents include
copolymerizable polyfunctional ethylenically unsaturated monomers
(e.g., 1,6-hexanediol diacrylate, trimethylolpropane triacrylate,
pentaerythritol tetraacrylate, and 1,2-ethylene glycol diacrylate);
ethylenically unsaturated compounds which in the excited state are
capable of abstracting hydrogen (e.g., acrylated benzophenones such
as described in U.S. Pat. No. 4,737,559 (Kellen et al.),
p-acryloxy-benzophenone, which is available from Sartomer Company,
Exton, Pa., monomers described in U.S. Pat. No. 5,073,611 (Rehmer
et al.) including
p-N-(methacryloyl-4-oxapentamethylene)-carbamoyloxybenzophenone,
N-(benzoyl-p-phenylene)-N'-(methacryloxymethylene)-carbodiimide,
and p-acryloxy-benzophenone); nonionic crosslinking agents which
are essentially free of olefinic unsaturation and is capable of
reacting with carboxylic acid groups, for example, in the third
monomer described above (e.g.,
1,4-bis(ethyleneiminocarbonylamino)benzene;
4,4-bis(ethyleneiminocarbonylamino)diphenylmethane;
1,8-bis(ethyleneiminocarbonylamino)octane; 1,4-tolylene
diisocyanate; 1,6-hexamethylene diisocyanate,
N,N'-bis-1,2-propyleneisophthalamide, diepoxides, dianhydrides,
bis(amides), and bis(imides)); and nonionic crosslinking agents
which are essentially free of olefinic unsaturation, are
noncopolymerizable with the first and second monomers, and, in the
excited state, are capable of abstracting hydrogen (e.g.,
2,4-bis(trichloromethyl)-6-(4-methoxy)phenyl)-s-triazine;
2,4-bis(trichloromethyl)-6-(3,4-dimethoxy)phenyl)-s-triazine;
2,4-bis(trichloromethyl)-6-(3,4,5-trimethoxy)phenyl)-s-triazine;
2,4-bis(trichloromethyl)-6-(2,4-dimethoxy)phenyl)-s-triazine;
2,4-bis(trichloromethyl)-6-(3-methoxy)phenyl)-s-triazine as
described in U.S. Pat. No. 4,330,590 (Vesley);
2,4-bis(trichloromethyl)-6-naphthenyl-s-triazine and
2,4-bis(trichloromethyl)-6-(4-methoxy)naphthenyl-s-triazine as
described in U.S. Pat. No. 4,329,384 (Vesley)).
[0094] Typically, the second monomer is used in an amount of 80-100
parts by weight (pbw) based on a total weight of 100 parts of
copolymer, and an additional monomer as described above is used in
an amount of 0-20 pbw based on a total weight of 100 parts of
copolymer. The crosslinking agent can be used in an amount of 0.005
to 2 weight percent based on the combined weight of the monomers,
for example from about 0.01 to about 0.5 percent by weight or from
about 0.05 to 0.15 percent by weight.
[0095] The acrylic PSAs useful for practicing the present
disclosure can be prepared, for example, in solvent or by a solvent
free, bulk, free-radical polymerization process (e.g., using heat,
electron-beam radiation, or ultraviolet radiation). Such
polymerizations are typically facilitated by a polymerization
initiator (e.g., a photoinitiator or a thermal initiator). The
polymerization initiator is used in an amount effective to
facilitate polymerization of the monomers (e.g., 0.1 part to about
5.0 parts or 0.2 part to about 1.0 part by weight, based on 100
parts of the total monomer content).
[0096] If a photocrosslinking agent is used, the coated adhesive
can be exposed to ultraviolet radiation having a wavelength of
about 250 nm to about 400 nm. The radiant energy in this range of
wavelength required to crosslink the adhesive is about 100
millijoules/cm.sup.2 to about 1,500 millijoules/cm2, or more
specifically, about 200 millijoules/cm.sup.2 to about 800
millijoules/cm.sup.2.
[0097] A useful solvent-free polymerization method is disclosed in
U.S. Pat. No. 4,379,201 (Heilmann et al.). Initially, a mixture of
second and third monomers can be polymerized with a portion of a
photoinitiator by exposing the mixture to UV radiation in an inert
environment for a time sufficient to form a coatable base syrup,
and subsequently adding a crosslinking agent and the remainder of
the photoinitiator. This final syrup containing a crosslinking
agent (e.g., which may have a Brookfield viscosity of about 100
centipoise to about 6000 centipoise at 23.degree. C., as measured
with a No. 4 LTV spindle, at 60 revolutions per minute) can then be
coated onto a substrate, for example, a polymeric film substrate.
Once the syrup is coated onto the substrate, for example, the
polymeric film substrate, further polymerization and crosslinking
can be carried out in an inert environment (e.g., nitrogen, carbon
dioxide, helium, and argon, which exclude oxygen). A sufficiently
inert atmosphere can be achieved by covering a layer of the
photoactive syrup with a polymeric film, such as silicone-treated
PET film, that is transparent to UV radiation or e-beam and
irradiating through the film in air.
[0098] Solvent-based adhesives may contain ingredients such as
those listed above, dissolved or dispersed in a solvent vehicle.
Water based adhesives would normally be based on emulsions of
(co)polymeric materials. Suitable (co)polymeric materials include
vinyl acetate and (meth)acrylic homopolymers and copolymers. The
phrase "(meth)acrylic homopolymers and copolymers" is typically
used to mean homopolymers and copolymers of one or more
(meth)acrylic esters (and acids) only, ethylene/vinyl acetate as
well as styrene/acrylic, vinyl chloride/acrylic, vinyl versatate
and others. Water based adhesives may have the disadvantage that
they generally require the additional use of drying ovens or heat
lamps to evaporate the water.
[0099] If a water vapor permeable pressure sensitive adhesive is
used, the air and water barrier article may be completely coated on
one side. If a water vapor impermeable pressure sensitive adhesive
is used, then the air and water barrier article is desirably only
partially coated with adhesive, typically in the range of about 10%
to 90%, more typically about 30% to 80%, most typically 40% to 70%,
of the surface area of the article. In other words, at least 10% to
90%, in some embodiments 20% to 70% or 30% to 60%, of the surface
area of the air and water barrier article is typically
adhesive-free in order to maintain sufficient water vapor
permeability of the article.
[0100] The adhesive may suitably be applied to the air and water
barrier article at a thickness of 0.001 inches to 0.1 inch (about
0.0254-2.54 millimeters). In some embodiments, the pressure
sensitive adhesive is applied at a thickness of 0.003 inches to
0.025 inches (about 0.0762-0.635 mm) or at a thickness of 0.005
inches to 0.02 inches (about 0.127-0.508 mm).
Adhesive Patterns
[0101] In some embodiments, the pressure sensitive adhesive is
impermeable to water vapor. In some of these embodiments, to retain
a desired level of water vapor permeance in the air and water
barrier articles, the adhesive is applied to the air and water
barrier article in a discontinuous manner in order to leave
portions of the major outer surface of the air and water barrier
article uncoated with adhesive.
[0102] In order to prevent the lateral movement of air between the
air and water barrier article and the substrate to which it is
bonded, and through lap joints of the air and water barrier
article, the adhesive coated areas of the air and water barrier
article can be made to intersect to isolate the uncoated areas,
thereby eliminating channels through which air can laterally move.
This can be achieved by any number of patterns, such as
intersecting circles with adhesive free centers, intersecting
squares or rectangles of adhesive, intersecting strips in a
checkered pattern, etc.
[0103] The adhesive may suitably be applied so as to cover 5% to
99% of the area of one side of the air and water barrier article.
In some embodiments, it is applied to cover between 10% and 90% of
the area, in some embodiments between 30% to 80% or 40% to 70% of
the area, to obtain a balance of adhesion and water vapor permeance
for the article.
[0104] Partial coatings of adhesive may be applied in a random
fashion or in a specific pattern. Some examples of partial coatings
of adhesive are described, for example, in U.S. Pat. No. 3,039,893
(Banigan, Jr.), U.S. Pat. No. 3,426,754 (Bierenbaum), U.S. Pat. No.
5,374,477 (Lawless), U.S. Pat. No. 5,593,771 (Lawless), U.S. Pat.
No. 5,895,301 (Porter), U.S. Pat. No. 6,495,229 (Carte), and U.S.
Pat. No. 6,901,712 (Lionel). In some embodiments, the adhesive is
provided from dispensing outlets on a first distribution manifold
and a second distribution manifold. The first distribution manifold
can move while the second distribution manifold is kept stationary.
Further details about this method can be found, for example, in
Int. Pat. Appl. Pub. No. WO 2015/126645 (Maier et al.) and WO
2015/126931 (Seabaugh et al.), the disclosure of which is
incorporated by reference in its entirety herein.
Liner
[0105] Air and water barrier articles according to the present
disclosure include a liner. Various liners may be useful in the
linered air and water barrier article according to the present
disclosure. In some embodiments, the liner comprises at least one
of a polyester film, polyethylene film, polypropylene film,
polyolefin coated polymer film, polyolefin coated paper, acrylic
coated polymer film, and polymer coated kraft paper. The polyolefin
coated film or paper may be polyethylene coated film or paper.
Examples of suitable commercially available liners include those
available under the trade designations "2.0 CL PET U4162/U4162" and
"4 BU DHP UE1094B/000" from Loparex, Hammond, Wis. and a red
pigmented, multilayer, thermoplastic olefin film containing a
proprietary blend of high density polyethylene and low density
polyethylene, having a thickness of about 63 micrometers (0.0025
inches), commercially available from Iso Poly Films, Incorporated,
Gray Court, S.C.
[0106] Referring now to FIG. 7, the present disclosure provides a
linered air and water barrier article 50 comprising an air and
water barrier article 21 according to the embodiment disclosed in
FIG. 2 and the corresponding text herein. In some embodiments, the
linered air and water barrier article 50 is a rolled article as
shown in FIG. 7. In some embodiments a peel adhesion between the
second major surface 32 of the liner 25 and the pressure sensitive
adhesive 12 is less than or equal to a peel adhesion between the
first major surface 30 of the liner 25 and the second major surface
13 of the air and water barrier article 21. In some embodiments,
the liner 25 is coated on at least one of the major surfaces 30, 32
with a release coating. In some embodiments, surface modification
is optionally used at the interface between the second major
surface 13 of the article 21 and the first major surface 30 of the
liner 25.
[0107] In some embodiments, the liner 25 is coated on at least one
of its major surfaces 30, 32 with a release coating. In some
embodiments both major surfaces 30, 32 of the liner 25 are coated
with a release coating. In this case, the release coating may the
same or different on each of the major surfaces 30, 32 of the liner
25. Examples of materials useful as release coatings for the liners
disclosed herein include acrylics, silicones, siloxanes,
fluoropolymers, and urethanes. For example, in some embodiments, a
liner useful in the roll according to the present disclosure is a
polyolefin-coated polyester film with silicone treatment on one
side, such as those commercially available under the trade
designation "48# CL PET H/H UE1095/000" from Loparex, Hammond, Wis.
In some embodiments, one side may have a silicone coating and the
other an acrylic coating. A silicone coating may be useful for
facilitating release of the pressure sensitive adhesive, while the
acylic coating may have higher peel adhesion to at least a portion
of the air and water barrier article (e.g., the polymeric
layer).
[0108] The liner may be produced using a variety of processing
techniques. For example, liner processing techniques such as those
disclosed in U.S. Pat. Appl. No. 2013/0059105 (Wright et al.) may
be useful to produce a liner suitable for practicing the present
disclosure. A suitable liner processing technique may include
applying a layer comprising a (meth)acrylate-functional siloxane to
a major surface of a substrate and irradiating that layer in a
substantially inert atmosphere comprising no greater than 500 ppm
oxygen with a short wavelength polychromatic ultraviolet light
source having at least one peak intensity at a wavelength of from
about 160 nanometers to about 240 nanometers. Irradiating can at
least partially cure the layer. In some embodiments, the layer is
cured at a curing temperature greater than 25.degree. C. The layer
may be at a temperature of at least 50.degree. C., 60.degree. C.
70.degree. C., 80.degree. C., 90.degree. C., 100.degree. C.,
125.degree. C., or at least 150.degree. C., in some embodiments, no
more than 250.degree. C., 225.degree. C., 200.degree. C.,
190.degree. C., 180.degree. C., 170.degree. C., 160.degree. C., or
155.degree. C.
[0109] In some embodiments, liner can be surface treated (e.g., at
least on the first major surface) to increase tack or adhesion
between the liner and the polymeric material. Examples of materials
or surface treatments useful for increase tack or adhesion between
the polymeric material and the first major surface of the liner
include any chemical or physical surface modifications to any of
the polymeric material, the first major surface of the liner, or
both. For example, a chemical surface modifier can be used. In some
embodiments, adhesion modification can be accomplished by selecting
a specific liner surface morphology to increase surface area and
physical interlocking of the polymeric material.
[0110] In many embodiments, the liner is impermeable to water
vapor. In these embodiments, the liner can peeled away from the air
and water barrier article after the air and water barrier article
is applied to a surface (e.g., a surface of a building component).
In other embodiments, at least a portion of the liner is not
removed from the air and water barrier article as described in
further detail below.
Coating Composition
[0111] In some embodiments of the linered air and water barrier
article according to the present disclosure, the article includes a
coating composition disposed between at least a portion of the
polymeric layer and the liner. The coating composition has a
different peel adhesion to the liner than the polymeric layer. In
some embodiments, the coating composition has a first peel adhesion
to the liner that is lower than a second peel adhesion between the
polymeric layer and the liner. Therefore, the coating composition
may be useful for reducing tack or adhesion between the polymeric
material and the liner. Generally, the coating composition is not
tacky and therefore would not be considered a PSA.
[0112] Useful coating compositions include any of a variety of
materials that are typically non-tacky and can be disposed between
the polymeric material and the liner. Examples of suitable coating
compositions include inks, release coatings, and slip coatings. In
some embodiments, the coating composition comprises at least one of
a polyamide, a polyurethane, a silyl-terminated polyether, a vinyl
polymer, an acrylic polymer, or a nitrocellulose polymer. A useful
silyl-terminated polyether can be prepared as a polymeric material
described above, for example, and increasing the amount of
inorganic filler in the polymeric material can decrease its peel
adhesion to the liner.
[0113] In some embodiments, the coating composition can be selected
from commercially available materials. For example, useful coating
compositions include a liquid, white ink available under the trade
designation "DT OPAQUE WHITE" from Sun Chemical Corporation,
Carlstadt, N.J., a liquid, red ink available under the trade
designation "SUNSPECTRO SB TRUWEATHER YS RED" from Sun Chemical
Corporation, a vinyl, white ink available under the trade
designation 13W1541 SOLVENT VINYLWHITE from Penn Color, Doylestown,
Pa., a water-based ink dispersion of titanium dioxide and binder
resin, available under the trade designation SPPFW1836936/G267 from
Sun Chemical Corporation, a water-based polyurethane dispersion,
available under the trade designation PERMAX 202 from The Lubrizol
Corporation, Cleveland, Ohio, and a solvent-based polyamide primer,
available under the trade designation POLYURETHANE PROTECTIVE TAPE
ADHESION PROMOTER 86A from 3M Company, St. Paul, Minn.
[0114] Referring now to FIG. 8, the present disclosure provides a
linered air and water barrier article 21 having opposing first and
second major surfaces 22, 13, a pressure sensitive adhesive 12
disposed on at least the first major surface 13 of the article 21,
a coating composition 42 disposed on the second major surface 22 of
the article 21, and a liner 25 having a first major surface 30 that
contacts the coating composition 42. The pressure sensitive
adhesive 12 contacts a second major surface 32 of the liner 25 when
wound up in the roll. The coating composition 42 has a first peel
adhesion to the first major surface 30 of the liner 25 that is
lower than a peel adhesion between the polymeric layer and the
first major surface 30 of the liner 25. The peel adhesion between
the second major surface 32 of the liner 25 and the pressure
sensitive adhesive 12 is generally less than or equal to the peel
adhesion between the first major surface 30 of the liner 25 and the
coating composition 42 and/or the polymeric material on the air and
water barrier article 21.
[0115] In these embodiment, the air and water barrier article need
not pass Modified Test 1 of ASTM D-1970/D-1970M-13 or Modified Test
2 of ASTM D-1970/D-1970M-13, or Modified Test 3 of ASTM
D-1970/D-1970M-13. For example, if the air and water barrier
article is used as a window sill tape as described below, it may be
flashed over another air and water barrier article that passes at
least one of Modified Test 1 of ASTM D-1970/D-1970M-13 or Modified
Test 2 of ASTM D-1970/D-1970M-13, or Modified Test 3 of ASTM
D-1970/D-1970M-13.
[0116] FIG. 8 illustrates a roll wound with the pressure sensitive
adhesive on the outside of the roll, which is useful for applying
the roll to a building component since the roll does not have to
first be unwound. In other embodiments, the roll may be wound with
the pressure sensitive adhesive on the inside of the roll as shown
in FIG. 7.
[0117] Referring now to FIG. 9, which is an end cross-section view
of the roll 50 described as multilayer construction 10, coating
composition 42 is disposed between a portion of the liner 25 and
the air and water barrier article 21. Coating composition 42 can be
positioned in various configurations and can have various widths
relative to the air and water barrier article. The liner 25 and air
and water barrier article 21 can contact each other in the portion
of the linered air and water barrier article that does not include
a coating composition. It is also possible to have first and second
coating compositions, each having a different peel adhesion to the
liner 25. Also shown in FIG. 9 is perforation 27 in the liner 25.
In some embodiments, the liner is slit at a location corresponding
to an edge of the coating composition 42. The edge of the coating
composition is where the coating composition stops when it does not
extend for the entire width of the air and water barrier article.
In some embodiments, the perforation 27 is within one centimeter, 5
millimeters (mm), 4 mm, 3 mm, 2 mm, or 1 mm of the edge of the
coating composition 42. The perforation may be made in the liner by
controlled-depth slitting.
[0118] A variety of slitting methods may be useful for slitting the
liner, for example, rotary cutting or laser cutting. For
perforations using a rotary cutter, the cutter may have notches to
leave some of the liner unslit to make perforation 27.
[0119] FIG. 0.10 is a top plan view of an embodiment of the
multilayer article 10 shown in FIG. 9 after a portion of the liner
25 has been removed. In this view, the liner 25 covers a portion of
the air and water barrier article but does not cover the coating
composition 42. In some embodiments, the liner extends to the
location of the edge of the coating composition, as this location
is defined above in any of its embodiments. In FIG. 10, coating
composition 42 extends along one side of the article 10 in the
machine direction and liner 25 extends along the opposite side of
the article 10 in the machine direction. In some embodiments,
including the illustrated embodiment, coating composition forms at
least one continuous strip extending along the length of the roll.
In some embodiments, the coating composition is discontinuous.
[0120] Although FIG. 9 illustrates that the liner is perforated,
the liner can also be torn without first being perforated, for
example, if it has been stretched in the machine direction. In
these embodiments, the liner may also be cut without first being
perforated.
[0121] As shown in the Examples, below, the coating composition can
influence the peel adhesion between the air and water barrier
article and the liner. In some embodiments, the peel adhesion
between the air and water barrier article and the liner is at least
15, 20, or 25 N/dm. The liner can be more easily removed from the
air and water barrier article where it overlays the coating
composition but can remain adhered to the air and water barrier
article at other locations. The peel adhesions can be determined as
described in the Examples below.
[0122] Any suitable coating method may be useful for applying the
coating compositions to the air and water barrier article and/or
the liner. For example, spray coating and gravure coating may be
useful.
Applications
[0123] In some embodiments, the presently disclosed air and water
barrier article has a moisture vapor transmission rate of 1 perms
or more according to ASTM E96 method. In some embodiments, the
presently disclosed air and water barrier article has a moisture
vapor transmission rate of 5 perms or more according to ASTM E96
method. In some embodiments, the article has a permeability of
greater than 10 perms according to ASTM E 96. In some embodiments,
thicknesses of the different layers used in the air and water
barrier article are varied to achieve desired permeability of the
article.
[0124] In some embodiments, the presently disclosed air and water
barrier article is applied on an exterior sheathing layer, which is
commonly plywood, oriented strand board (OSB), foam insulation
sheathing, nonwoven glass mat faced gypsum sheathing board, or
other conventional sheathing materials commonly used in the
construction industry. Useful exterior cladding layer is made up of
brick, concrete blocks, reinforced concrete, stone, vinyl siding,
fiber cement board, clapboard, metal panels, or other known
exterior siding materials. In some embodiments, the air and water
barrier article is applied to a roofing deck, an attic floor or
other attic surface, a boundary between a wall, roof system, and/or
foundation, other interior or exterior surfaces of a structure, or
used as flashing around a roof penetration.
[0125] Building components include panels and other constructions
before, during, or after they become part of an architectural
structure.
[0126] The air and water barrier article according to the present
disclosure can be applied to a building component by adhering at
least a portion of the pressure sensitive adhesive on the roll in
any of the above embodiments to a surface of an building component,
so that the air and water barrier article is affixed to the surface
of the building component. When the roll is unwound, the liner
releases from the pressure sensitive adhesive and remains adhered
to at least the second coating composition on the air and water
barrier article (and in some cases the first coating composition)
even when a peel adhesion between the second major surface of the
liner and the pressure sensitive adhesive is equal to the second
peel adhesion. Adhering the roll to the building component can be
carried out before or after the roll is unwound. In some
embodiments, the roll is adhered to the building component before
it is unwound. In some embodiments, the roll is at least partially
unwound before it is adhered to the building component. In
embodiments in which the roll is wound with the pressure sensitive
adhesive on the inside of the roll, as shown in FIG. 7, the roll
may be unwound at least partially before the roll is adhered to the
building component.
[0127] Next the liner can be peeled away from the air and water
barrier article. Peeling the liner away from the first and second
coating composition is optional and depends on whether a water
vapor permeable liner is used and whether water vapor permeability
is desired.
[0128] In some embodiments, including the embodiment illustrated in
FIGS. 9 and 10, the liner is removed from a portion of the air and
water barrier article while leaving a portion of the liner disposed
on the major surface of the polymer layer. When the liner is
impermeable, this can result in an air and water barrier article
with different permeabilities in different zones. In these
embodiments, the linered air and water barrier article according to
the present disclosure is useful for the sill pan flashing of a
window. It is desirable to have a non-permeable sill piece under
the window and to have a permeable section of the tape to flash
onto the vertical wall sections of the flashing. The non-permeable
section offers the greatest protection in the sill, while the
permeable section offers a way for moisture to get out in the event
of a failed flashing installation. The elastic porous layer in the
air and water barrier article allows it to have sufficient
elongation to be able to stretch into the corner detail as a
continuous sheet without seams and lay flat.
[0129] When the air and water barrier article according to the
present disclosure is used as a sill tape, the width of the article
is at least 10 centimeters and can be up to 30 centimeters. These
widths allow the tape to be positioned in a window sill with the
impermeable portion covering the sill and the permeable portion on
the flashing.
[0130] In other applications, the air and water barrier article
according to the present disclosure can have a wide variety of
widths. In some embodiments, the width of the article is at least
1.9 centimeters or at least 2.5 centimeters. In some embodiments,
the width of the article is at least 5 centimeters. In some
embodiments, the width of the article is at most 10 centimeters. In
some embodiments, the width of the article is up to 45 centimeters
or up to 75 centimeters.
Method of Making Some Embodiments of Air and Water Barrier
Articles
[0131] In some embodiments, the presently disclosed air and water
barrier articles can be made as described in U.S. Pat. No.
4,984,584 (Hansen et al.) using equipment as shown in FIG. 5.
Elastomeric strands 410 from a beam 411 are unwound under tension
controlled by driven press roll 412 and through comb 414. A first
porous layer 415, having a polymeric layer disposed thereon along,
with a second porous layer 417, from supply drums 416 and 418,
respectively, or directly from the forming machine, if desired, are
brought into contact with the elastomeric strands and with each
other between rubber-covered squeeze roll 419 and knurled steel
squeeze roll 420, the latter dipping into a pan 421 containing a
fluid binder mixture 422 and depositing the binder mixture
throughout the second porous layer 417. The composite web passes
directly into a drying oven 424 and thence between pull drums 425
and 426. The web next passes around roll 427, between heating
platens 428 and 429, around idler rolls 431 and surface winder roll
430, and is wound up to form stock roll 432.
[0132] Squeeze rolls 419 and 420 rotate at a considerably greater
surface speed than beam 411, and the elastomeric strands 410 are
accordingly stretched a corresponding amount. This stretch is
maintained by operating pull drums 425 and 426 and turn-around drum
427 at approximately the same speed compared with rollers 419 and
420. Surface winder roll 430 and wind-up drum 432, however, are
again operated at a slower speed to permit shrinkage of the web as
it passes between the heater platens 428 and 429. The composite web
434, which is smooth as it reaches the roll 427, becomes
increasingly puckered, crimped or shirred as it passes through the
heating zone, the result being further indicated in FIG. 6.
[0133] The heat supplied by the platens 428 and 429 is sufficient
to cause considerable fuming of the sheet material and to relax the
structure sufficiently to permit the elastomeric strands to retract
and produce the desired degree of puckering, crimping or shining as
controlled by the speed of the surface winder roll. The temperature
may be regulated by adjusting both the energy input to the platens
and the distance between the platens and the web. The duration of
the heat treatment may be regulated, for a given length of platen,
by adjusting the speed of travel of the web, sufficient time being
provided to permit retraction of the web to the desired degree. The
platens are maintained at a temperature sufficient to keep the web
taut during the shrinking operation between rolls 427 and 430 at
the speed indicated but not so high as to cause deterioration of
the web as evidenced by excessive fuming and discoloration thereof.
The shined or crimped product is dimensionally stable, the heat
treatment serving to provide an effective degree of heat-setting or
stabilizing, and neither shrinks nor expands when allowed to stand
at normal temperatures and under no external stress; and it returns
to such dimensions when first stretched and then permitted to
retract.
[0134] In some embodiments concentrated natural rubber latex or
synthetic rubber latex can be used as the fluid binder mixture.
Other elastomers or blends of elastomers having similar properties
may be used.
[0135] In some embodiments, instead of using a fluid binder
mixture, a hot melt adhesive can be otherwise disposed between the
elastomeric strands and the second porous layer and between the
elastomeric strands and the first porous layer.
[0136] Following are embodiments and combinations of embodiments
according to the present disclosure:
Embodiment 1
[0137] An article comprising:
[0138] a polymeric layer disposed on and covering a first major
surface of an elastic porous layer, wherein the polymeric layer and
the elastic porous layer together form an air and water barrier
that is water vapor permeable;
[0139] an adhesive layer disposed on a second major surface of the
elastic porous layer opposite the polymeric layer; and
[0140] a liner disposed on a major surface of the polymeric layer
opposite the first major surface of the elastic porous layer,
wherein the liner is water vapor impermeable.
Embodiment 2
[0141] The article of embodiment 1, further comprising a coating
composition disposed between at least a portion of the polymeric
layer and the liner, wherein the coating composition has a first
peel adhesion to the liner that is lower than a second peel
adhesion between the polymeric layer and the liner.
Embodiment 3
[0142] The article of embodiment 2, wherein the second peel
adhesion is at least 15 N/dm.
Embodiment 4
[0143] The article of embodiment 2 or 3, wherein the liner is cut
at a location corresponding to an edge of the coating
composition.
Embodiment 5
[0144] The article of embodiment 2 or 3, wherein the liner does not
cover the coating composition.
Embodiment 6
[0145] An article comprising:
[0146] a polymeric layer disposed on and covering a first major
surface of an elastic porous layer, wherein the polymeric layer and
the elastic porous layer together form an air and water barrier
that is water vapor permeable;
[0147] an adhesive layer disposed on a second major surface of the
elastic porous layer opposite the polymeric layer; and
[0148] a liner disposed on a major surface of the polymeric layer
opposite the first major surface of the elastic porous layer,
wherein the liner is water vapor impermeable and covers only a
portion of the major surface of the polymeric layer.
Embodiment 7
[0149] The article of any one of embodiments 1 to 6, wherein the
article passes at least one of Modified Test 1 of ASTM
D-1970/D-1970M-13, Modified Test 2 of ASTM D-1970/D-1970M-13, or
Modified Test 3 of ASTM D-1970/D-1970M-13.
Embodiment 8
[0150] The article of any one of the preceding embodiments, wherein
a portion of the air and water barrier not covered by the liner has
a vapor transmission rate of greater than or equal to 1 perms.
Embodiment 9
[0151] The article of any one of the preceding embodiments, wherein
the elastic porous layer comprises at least one of a plurality of
elastomeric strands, elastic net, elastic nonwoven material,
elastic woven fabric, elastic knitted fabric, elastic foam, elastic
microperforated film, and combinations thereof.
Embodiment 10
[0152] The article of any one of the preceding embodiments, wherein
the article has an elongation of at least 90% in at least one
direction.
Embodiment 11
[0153] The article of any one of the preceding embodiments, wherein
the polymeric layer comprises a polyoxyalkylene polymer having at
least one end group derived from an alkoxy silane.
Embodiment 12
[0154] The article of embodiment 11, wherein all of the end groups
of the polyoxyalkylene polymer are silyl terminated.
Embodiment 13
[0155] The article of any one of the preceding embodiments, wherein
the elastic porous layer comprises at least one of polyester,
polylactic acid, polyolefin, polyamide, polyurethane, or rayon.
Embodiment 14
[0156] The article of any one of the preceding embodiments, wherein
the elastic porous layer is a nonwoven comprising at least one of
polyester, polylactic acid, polyolefin, polyamide, polyurethane, or
rayon.
Embodiment 15
[0157] The article of any of embodiments 1 to 14 wherein the
elastic porous layer is a selected from an extruded netting, a
scrim, and combinations thereof.
Embodiment 16
[0158] The article of any of embodiments 1 to 15 wherein the
elastic porous layer comprises a woven material.
Embodiment 17
[0159] The article of any of embodiments 1 to 16 wherein the
elastic porous layer comprises blown microfibers.
Embodiment 18
[0160] The article of any of embodiments 1 to 17 wherein the
elastic porous layer has a water strike through time of less than
400 seconds.
Embodiment 19
[0161] The article of any of the preceding embodiments wherein the
article has an elongation of at least 105% in air least one
direction.
Embodiment 20
[0162] The article of embodiment 11 or 12 wherein the
polyoxyalkylene polymer further comprises at least one silyl
modified branched group.
Embodiment 21
[0163] A method of applying an air and water barrier article, the
method comprising:
[0164] adhering at least a portion of the adhesive layer on a roll
of the article of any one of embodiments 1 to 20 to a surface of a
building component, so that the article is affixed to the surface
of the building component;
[0165] unwinding at least a portion of the roll, wherein during the
unwinding, the liner remains disposed on the major surface of the
polymeric layer opposite the first major surface of the elastic
porous layer; and,
[0166] peeling at least a portion of the liner away from a portion
of the article.
Embodiment 22
[0167] The method of embodiment 21, further comprising leaving a
portion of the liner disposed on the major surface of the polymer
layer.
[0168] Embodiments of the present disclosure have been described
above and are further illustrated below by way of the following
Examples, which are not to be construed in any way as imposing
limitations upon the scope of the present disclosure. On the
contrary, it is to be clearly understood that resort may be had to
various other embodiments, modifications, and equivalents thereof
which, after reading the description herein, may suggest themselves
to those skilled in the art without departing from the spirit of
the present disclosure and/or the scope of the appended claims.
EXAMPLES
[0169] The following examples are intended to illustrate exemplary
embodiments within the scope of this disclosure. Notwithstanding
that the numerical ranges and parameters setting forth the broad
scope of the disclosure are approximations, the numerical values
set forth in the specific examples are reported as precisely as
possible. Any numerical value, however, inherently contains certain
errors necessarily resulting from the standard deviation found in
their respective testing measurements. At the very least, and not
as an attempt to limit the application of the doctrine of
equivalents to the scope of the claims, each numerical parameter
should at least be construed in light of the number of reported
significant digits and by applying ordinary rounding
techniques.
Materials
TABLE-US-00001 [0170] KANEKA MS POLYMER S203H A liquid,
silyl-terminated polyether derived from a polyether polymer
backbone and having methyldimethoxysilane functional groups and a
viscosity of 6000 to 10,000 centiPoise, available under the trade
designation KANEKA MS POLYMER S203H from Kaneka North America, LLC,
Pasadena, TX. AEROSIL R202 A hydrophobic fumed silica after treated
with a polydimethylsiloxane, available under the trade designation
AEROSIL R202 from Evonik Corporation, Parsippany, NJ. OMYACARB 5-FL
A beneficiated calcium carbonate having a mean particle size of 6.3
micrometers and a calcium carbonate content of 98%, available under
the trade designation OMYACARB 5-FL from Omya Incorporated,
Cincinnati, OH. TIONA 696 A non-chalking, chlorie-process rutile
titanium dioxide pigment having a titanium dioxide content of 92%,
and a surface treatment of alumina, silica, organic, available
under the trade designation TIONA 696 from Cristal, Hunt Valley,
MD. DYNASYLAN DAMO-T A liquid, bifunctional organosilane having two
reactive amino groups and hydrolyzable inorganic methoxysilyl
groups, available under the trade designation DYNASYLAN DAMO- T
from Evonik Corporation, Parsippany, NJ. DYNASYLAN VTMO A liquid,
bifunctional organosilane having a reactive vinyl group and a
hydrolyzable inorganic trimethoxysilyl group, available under the
trade designation DYNASYLAN VTMO from Evonik Corporation,
Parsippany, NJ. NEOSTAN U-220H A liquid catalyst based on dibutyl
tin bis(acetylacetoacetonate) having a tin content of 27.5%,
available under the trade designation NEOSTAN U-220H from Nitto
Kasei Company, Ltd., Osaka, Japan. IOA isooctyl acrylate AA acrylic
acid IRGACURE 651 2-dimethoxy-2-phenylacetophenone, a
photoinitiator available under the trade designation IRGACURE 651
from available from BASF Corporation, Florham Park, NJ. FORAL 85LB
A glycerol ester of highly hydrogenated wood rosin, available under
the trade designation FORAL 85LB from Pinova Incorporated,
Brunswick GA. Triazine
2,6-bis-trichoromethyl-6-(3,4-dimethoxyphenyl)-s-triazine CLOPAY
BR-134U A white, microporous, breathable film having an embossed
pattern thereon, an areal weight of 19 grams/square meter, and a
moisture vapor transmission rate of (7500 grams H2O/ day), believed
to be mixture of a greater amount of linear low density
polyethylene and a lesser amount of low density polyethylene, the
mixture being modified with calcium carbonate and a styrene
triblock polymer, available under the trade designation CLOPAY
BR-134U White Breathable Film from Clopay Plastic Products Company,
Mason, OH. LINER 1 A 51 micrometer (0.002 inch) thick, polyester
film having a silicone treatment on both sides, available as 2.0 CL
PET U4162/U4162 from Loparex, Hammond, WI. UCON 50-HB-400 A
monobutyl ether of a linear polymer of ethylene oxide:propylene
oxide (1:1) polyglcyol, having a number average molecular weight
(Mn) of approximately 1230 and a viscosity index (VI) of 220 (ASTM
D2270, IP 226), available under the trade designation UCON
LUBRICANT 50-HB-400 from Dow Chemical Company, Midland, MI. 2CEA
2-Carboxyethyl acrylate (beta-carboxyethyl acrylate), a slightly
viscous liquid containing 30-35 wt % of 2-carboxyethyl acrylate,
50-60 wt % of acrylic acid oligomers, and 10-20 wt % of acrylic
acid, having an acid number of 6.4 milliequivalents/gram, available
from Bimax Incorporated, Glen Rock, PA. REEMAY 2024 A spunbond
polyester fabric having an areal weight of 71.4 grams/square meter,
a thickness of 0.31 millimeters, and a TEXTEST Air Perm of (1626
liters/second)/square meter (320 cubic feet/minute)/square foot),
available under the trade designation REEMAY 2024 from Fiberweb
Filtration Business, Old Hickory, TN. MPG S000695142 An elastic
material containing 91% Polyester and 9% SPANDEX woven fabric,
having an areal weight of 116 grams/square meter, available as MPG
S000695142 from Milliken & Company, Spartanburg, SC. FOAM 1 A
foam sample was obtained by cutting a foam piece from a 90612 3M
TEGADERM Foam Adhesive Dressing (3M Company, St. Paul, Minn.) such
that the foam piece freely separated from all other parts of the
dressing. FOAM 2 A foam having a density between 0.028 and 0.034
grams/ cubic centimeter (1.75 and 2.10 pounds/cubic foot), a
minimum elongation of 90%, and a minimum tensile strength of 110
KiloPascals (16.0 pounds/square inch), available as #6 in Foam Kit
from Rogers Foam Corporation, Somerville, MA. FOAM 3 A foam having
a density between 0.027 and 0.034 grams/ cubic centimeter (1.7 and
2.1 pounds/cubic foot), a minimum elongation of 240%, and a minimum
tensile strength of 207 KiloPascals (30 pounds/square inch),
available as #26B in Foam Kit from Rogers Foam Corporation,
Somerville, MA. FINON C3019NW A white, pattern spunbonded, nonwoven
fiber of 100% polyester containing no chemical binder and having an
areal weight of 18.6 grams/square meter (0.55 ounces/square yard),
a product of Kolon Industries, Incorporated, Korea and available
under the trade designation FINON C3019NW from Midwest Filtration
LLC, Cincinnati, OH. SONTARA 8005 A white, spunlace polyester
nonwoven having an areal weight of 67.8 grams/square meter and a
thickness of 0.51 millimeters (0.020 inches), available under the
trade designation SONTARA Style 8005 from Sontara America,
Incorporated, Candler, NC. Spray Adhesive A synthetic
elastomer-based, high strength, fast contact-type spray adhesive,
available as Hi-Strength 90 Spray Adhesive from 3M Company, St.
Paul, MN. Elastomeric Strands Chlorine resistant elastic fibers
having an elongation at break of greater than 550% and a denier of
210, available under the trade designation RADICISPANDEX TYPE S17-B
from RadiciSpandex Corporation, Gastonia, NC. LINER 2 A 51
micrometer (0.002 inch) thick untreated polyester film. LINER 3 A
77 micrometers (0.003 inches) thick, polyolefin-coated polyester
core with silicone treatment on one side, available under the trade
designation 48# CL PET H/H UE1095/000 from Loparex, Hammond, WI.
LINER 4 An 89 micrometers (0.0035 inches) thick, cast polypropylene
film having one glossy side and one matte side. LINER 5 A polyester
film having a thickness of 36 micrometers (0.0014 inches) and
having a polyolefin primer on one side and silicone treatment on
the opposite side, available under the trade designation 2PAKN from
Mitsubishi Polyester Film, Incorporated, Greer, SC. LINER 6 LINER 3
was coated on the non-siliconized side according to Synthesis
Example 1 of US 2013/0004749 A1, except that a gravure coater was
used in place of a Meyer bar. Ink 1 A liquid, white ink, available
under the trade designation DT OPAQUE WHITE from Sun Chemical
Corporation, Carlstadt, NJ. GENIOSIL XL 65 A liquid, alkoxysilane
having an O-methyl carbamate organofunctional group,
N-Dimethoxy(methyl)silylmethyl-O- methyl-carbamate, having utility
as a water scavenging compound, available under the trade
designation GENIOSIL XL 65 from Wacker Chemie AG, Munchen,
Germany.
Test Methods
Nail Sealability
[0171] Nail sealability of air and water barrier articles was
evaluated generally as described in ASTM D-1970/D-1970M-13:
"Standard Specification for Self-Adhering Polymer Modified
Bituminous Sheet Materials Used as Steep Roofing Underlayment for
Ice Dam Protection", Paragraph 7.9: "Self Sealability. Head of
Water Test" with some modifications. All materials were conditioned
at (23.degree. C. (73.degree. F.)) for at least 24 hours prior to
use. Three different modified tests were employed. Samples were
considered to have passed the test if a rating of "A" or "B" was
achieved.
Modified Test 1 of ASTM D-1970/D-1970M-13
[0172] A plywood substrate having a thickness of 1.25 cm (0.5
inches) was employed; four nails were driven through the air and
water barrier article into the plywood substrate until 6.35
millimeters (0.25 inches) remained above the exposed surface of the
air and water barrier article; and a red dye was added to the
water. After exposure the surface of plywood substrate in contact
with the air and water barrier article (referred to herein as the
"topside"), and the surface of the plywood substrate opposite the
topside (referred to herein as the "bottomside") were inspected
visually by unaided eye for signs of water leakage as determined by
the presence of red-stained areas around each of the four nails.
Such stained areas would be indicative of failure of the air and
water barrier article to form a seal around the nails. Samples were
rated "A" if 3 or 4 of the nail areas on the plywood substrate were
free of dye staining; "B" if 2 of the nail areas on the plywood
substrate were free of dye staining; and "C" if 1 or 0 of the nail
areas on the plywood substrate were free of dye staining.
Modified Test 2 of Astm D-1970/D-1970M-13
[0173] Modified Test 2 was conducted in the same manner as Modified
Test 1 with the following change. The four nails were driven
through the air barrier article into the plywood substrate until
the nail head contacted the top surface of the air and water
barrier article, then the nail was backed out until 6.35
millimeters (0.25 inches) remained above the exposed surface of the
air and water barrier article.
Modified Test 3 of ASTM D-1970/D-1970M-13
[0174] Modified Test 3 was conducted in the same manner as Modified
Test 2 with the following modification. The nails were not backed
out.
Moisture Vapor Transmission Rate
[0175] The moisture vapor transmission rates of air and water
barrier articles were evaluated generally as described in ASTM
E96/E96M-13: "Standard Test Methods for Water Vapor Transmission of
Materials" using Paragraph 11: Dessicant Method at (23.degree. C.
(73.degree. F.)) and 50% relative humidity, with the following
modifications. Six data points were obtained and used to calculate
a permeance value. The six individual values were used to determine
an average permeance value which was reported in units of
Perms.
180.degree. Angle Peel Adhesion Test 1 (Easy Side Release=Adhesive
Strength)
[0176] The 180 degree angle peel adhesion strength between the
liner and pattern coated pressure sensitive adhesive, also referred
to herein as the "easy side release", was measured on a laminate of
liner/pattern coated pressure sensitive adhesive/porous layer.
Adhesive strength was measured after aging for seven days at
23.degree. C. and 50% relative humidity. A 2.54 centimeter wide by
approximately 20 centimeter (1 inch by 8 inch) long sample of the
laminate was cut using a specimen razor cutter. The exposed liner
surface was attached lengthwise to the previously cleaned aluminum
platen surface of a peel adhesion tester (Model SP3M90, IMASS
Incorporated, Accord, Mass.). The laminate was then rolled down one
time in one direction with a 2 kilograms (4.4 pounds) rubber roller
at a rate of 230 centimeters/minute (90 inches/minute). The
pressure sensitive adhesive/porous layer was carefully lifted away
from the liner adhered to the platen surface, doubled-back at an
angle of 180 degrees, and secured to the clamp of the peel adhesion
tester. The 180 degree angle peel adhesion strength was then
measured as the pressure sensitive adhesive/porous layer was peeled
from the liner at a rate of 230 centimeters/minute (90
inches/minute). A minimum of two test specimens were evaluated with
results obtained in ounces/inch which were used to calculate the
average release strength. Release testing was conducted under
Condition A described in 180.degree. Angle Peel Adhesion Test 2
(Tight Side Release=Liner Release) below.
180.degree. Angle Peel Adhesion Test 2 (Tight Side Release=Liner
Release)
[0177] The 180 degree angle peel adhesion strength between the
liner and polymeric material, also referred to herein as the "tight
side release", was measured on a laminate of liner/polymeric
material/porous layer. The same procedure as described for
"180.degree. Angle Peel Adhesion Test 1 (Easy Side Release=Adhesive
Strength)" was used with the following modification. The polymeric
material/porous layer was carefully lifted away from the liner
adhered to the platen surface, doubled-back at an angle of 180
degrees, and secured to the clamp of the peel adhesion tester. The
180 degree peel adhesion strength between the liner and polymeric
material was measured after all aging conditions (A, B, and C)
given below.
[0178] A) After 7 days at 23.degree. C. (73.degree. F.) and 50%
relative humidity (RH);
[0179] B) After 7 days at 70.degree. C. (158.degree. F.) followed
by equilibration for 4 hours at 23.degree. C./50% RH;
[0180] C) After 7 days at 32.degree. C. (90.degree. F.) followed by
equilibration for 4 hours at 23.degree. C./50% RH.
In some instances the adhesion between the liner and the polymeric
material and/or the adhesion between the polymeric material and the
porous layer was greater than the internal (cohesive) strength of
the polymeric material. This resulted in splitting of the polymeric
material, and was reported as "Cohesive Failure".
Elongation
[0181] Tensile properties of coated air barrier articles were
evaluated generally as described in ASTM D882-12: "Standard Test
Method for Tensile Properties of Thin Plastic Sheeting" with the
following modifications. Three straight section specimens measuring
12.5 mm (0.5 inches) wide, 152 millimeters (6 inches) long, and
having a thickness generally between approximately 0.15 and 0.76
millimeters (0.006 to 0.030 inches) were cut from film samples in
the downweb (DW; also referred to as the machine direction (MD))
and crossweb (CW) directions and conditioned for a minimum of 24
hours at 23+/-2.degree. C. and 50% relative humitdity+/-5% prior to
testing. The separation distance between parallel grips was 100 mm
(4 inches), the crosshead speed was 51 millimeters/minute (2
inches/minute). The separation rate, force measurements, and data
calculations were carried out by the system controller. The average
of two test samples was reported.
Stress Relaxation
[0182] Stress Relaxation properties of coated air barrier articles
were evaluated as follows. Samples were conditioned for a minimum
of 24 hours at 23+/-2.degree. C. and 50% relative humidity+/-5%
prior to testing. A straight section specimen measuring 25.4
millimeters (1 inch) wide, by 152 millimeters (6 inches) long was
cut in the machine direction (MD). The sample was inserted with no
slack or stretch into the grips of a tensile machine (Model Sintech
500/s, MTS Systems Corporation, Eden Prairie, Minn.) with an
initial separation distance between parallel grips of 100
millimeters (4 inches). The sample was elongated at a crosshead
speed of 1520 millimeters/minute (60 inches/min) until it reached
50% elongation. This position was held for 5 minutes. The crosshead
then returned to 0% elongation, completing the cycle. The
separation rate, force measurements, and data calculations were
carried out by the system controller. The initial load at 50%
elongation and the load after 5 minutes at 50% elongation were
recorded. The stress relaxation was calculated as (1-(load after 5
minutes/initial load))*100 and reported in %. The load values were
reported in pounds force (lbf) and Newtons (N).
Water Strike Through
[0183] The moisture dissipation capability of the polymeric coated
porous layer was characterized according to WSP 70.3
(08)--"Standard Test Method for Nonwoven Coverstock Liquid
Strike-Through Time Using Simulated Urine" with the following
modifications. No absorbent pad was put under the test specimen.
The samples were all tested on the porous layer opposite the
polymeric coating. Instead of using 5 mL of simulated urine, 3
milliliters of distilled water was used. A plate measuring 101.6
millimeters (4 inches).times.101.6 millimeters (4
inches).times.25.4 millimeters (1 inch) thick was placed on top of
the specimen. The water was placed into a cylinder cut through the
plate with a diameter of 25.4 millimeter (1 inch). A stopwatch was
used instead of an electronic timer. The stopwatch was started as
soon as the water contacted the porous layer, and was stopped once
the water had completely penetrated into the porous layer. The time
for the 3 milliliters of water to completely penetrate into the
porous layer was recorded in seconds and reported as the Strike
Through Time of the polymeric coated porous layer.
Water Absorption Capacity
[0184] The absorption capacity of the polymeric coated porous layer
was determined as follows. A 107.95 millimeters (4.25
inches).times.107.95 millimeters (4.25 inches) sample was weighed
and then placed in to a bath of water for 5 minutes. The material
was then taken out of the bath and hung by a clip for 1 minute. The
material was then reweighed to determine the weight of the water
absorbed in grams. The Water Absorbance Capacity was calculated by
subtracting the initial weight of the material from the final
weight after soaking. The absorption values were reported in
grams
EXAMPLES
Example 1
[0185] An air and water barrier article having an elastic porous
layer partially impregnated and covered on one side with a
polymeric material and having a pressure sensitive adhesive layer
disposed on the side of the elastic porous layer opposite that
coated with the polymeric material was prepared as follows. The
polymeric material composition was provided by charging the
following materials into a mixing vessel which was then placed in a
dual asymmetric centrifuge mixer: 39.8 parts by weight (hereinafter
abbreviated as "pbw") of a silyl-terminated polyether, KANEKA MS
POLYMER 5203H, 1.25 pbw of hydrophobic fumed silica, AEROSIL R202,
26.7 pbw of calcium carbonate OMYACARB 5-FL, and 4.4 pbw of
titanium oxide, TIONA 696. After mixing at 2500 rpm for four
minutes 0.87 pbw of an aminosilane, DYNASYLAN DAMO-T, 0.87 pbw of a
vinyl trimethoxysilane, DYNASYLAN VTMO, and 0.19 pbw of a tin
catalyst, NEOSTANN U-220H, were added and mixed at 2500 rpm for two
minutes. This final mixture was used to coat LINER 1 using a notch
bar coater having a gap setting that was 0.30 millimeters (0.012
inches) greater than the thickness of the release film. The
polymeric material-coated release film was then laminated to an
elastic porous layer, FOAM 1, at room temperature (23.degree. C.
(73.degree. F.)) using a hand roller and light pressure. This
laminate construction was cured at 93.degree. C. (200.degree. F.)
for 8 hours. This gave a self-sealing air and water barrier article
(continuous layer of polymeric material on one side of the elastic
porous layer) having a liner on the side of the polymeric coating
opposite that of the elastic porous layer.
[0186] A pressure sensitive adhesive precursor composition was
prepared by mixing 99 parts pbw isooctyl acrylate (IOA), 1 pbw
acrylic acid (AA) and 0.04 pbw of a photoinitiator, IRGACURE 651.
This mixture was partially polymerized under a nitrogen atmosphere
by exposure to low intensity ultraviolet radiation to provide a
coatable syrup having a viscosity of about 4000 cps. An additional
0.26 pbw of IRGACURE 651, 0.13 pbw of a Triazine, and 6 pbw of a
tackifier, FORAL 85LB, were added to the syrup and mixed until all
of the components had completely dissolved to give a pressure
sensitive adhesive precursor composition.
[0187] The adhesive precursor composition was then coated onto a
siliconized polyethylene coated Kraft paper liner using a notch bar
with a 0.076 mm (0.003 inches) gap setting greater than the
thickness of the liner. The adhesive precursor was then exposed to
an ultraviolet radiation source having a spectral output from
300-400 nanometers with a maximum at 351 nanometers in a
nitrogen-rich environment. An irradiance of about 9.0
milliWatts/square centimeter was used during the exposure time,
resulting in a total energy of 1800 milliJoules/square centimeter.
The result was a pressure sensitive adhesive coated liner.
[0188] For nail sealability evaluation the pressure sensitive
adhesive was transfer laminated from the paper liner to a 12.7
millimeter (0.5 inch) thick piece of plywood substrate using hand
pressure. Next, the self-sealing air and water barrier article was
laminated by hand to the plywood substrate such that the exposed
surface of the elastic porous layer covered the pressure sensitive
adhesive layer. The liner attached to the polymeric coating was
then removed. The plywood substrate having an adhesive coated,
self-sealing air and water barrier article thereon was then
evaluated for nail sealability using test method 1.
[0189] Measurement of moisture vapor transmission rates and tensile
and elongation properties were conducted on the elastic
self-sealing air and water barrier article (continuous layer of
polymeric material on one side of the elastic porous layer) that
resulted from removal of the liner from the polymeric coating prior
to testing unless otherwise noted below.
[0190] "Tight Side Release" was measured on the construction of the
elastic self-sealing air and water barrier article (continuous
layer of polymeric material on one side of the elastic porous
layer) having a liner on the side of the polymeric coating opposite
that of the elastic porous layer.
Example 2
[0191] Example 1 was repeated with the following modifications. The
elastic porous layer used was FOAM 2.
Example 3
[0192] Example 1 was repeated with the following modifications. The
elastic porous layer used was FOAM 3.
Example 4
[0193] Example 1 was repeated with the following modifications. The
elastic porous layer used was MPG S000695142. This construction was
also tested for Stress Relaxation, Water Strike Through, and Water
Absorption Capacity after LINER 1 was removed.
Comparative Example 1
[0194] Example 1 was repeated with the following modifications. A
porous layer (REEMAY 2024) was used in place of the elastic porous
layer, FOAM 1. This material was also tested for Water Strike
Through.
Illustrative Example 5
[0195] A pressure sensitive adhesive precursor composition on a
siliconized polyethylene coated Kraft paper liner was prepared as
described in Example 1. REEMAY 2024 was then laminated using hand
pressure to the exposed pressure sensitive adhesive. Next, the
siliconized polyethylene coated Kraft paper liner was removed and
replace with LINER 1. This construction was then tested for "Easy
Side Release".
Example 6
[0196] Elastomeric Strands were cut to 29.5 centimeters (11.6
inches) in length. Three Elastomeric Strands were held together and
the ends tied to two screws spaced 118 centimeters (46.5 inches)
apart in a plywood board. This was repeated for 27 more sets of
three Elastomeric Strands, with a spacing of 0.64 centimeters (0.25
inches) between the sets.
[0197] A porous layer, FINON C3019NW, having LINER 1 on one side
was treated with Spray Adhesive on the side opposite that in
contact with the LINER 1. The resulting adhesive treated porous
layer with liner was then slid under the sets of Elastomeric
Strands mounted on the plywood board. Next, the upper, exposed
surface of the Elastomeric Strands was treated with Spray
Adhesive.
[0198] A self-sealing air and water barrier article (continuous
layer of polymeric material on one side of the elastic porous
layer) was prepared as described in Example 1 and its LINER
removed, with the following modification. A porous layer, FINON
C3019NW, was used in place of the elastic porous layer FOAM 1. This
self-sealing air and water barrier article was the laminated using
hand pressure on top of the exposed, adhesive treated Elastomeric
Strands. The multilayered construction was allowed to dry at room
temperature for about 24 hours.
[0199] The ends of the Elastomeric Strands were then cut from the
plywood board, the LINER 1 was removed, and the resulting
construction treated with a heat gun on high setting for a total of
about five minutes to give an elastic self-sealing air and water
barrier article.
[0200] For nail sealability evaluation a paper liner containing
pressure sensitive adhesive prepared as described in Example 1 was
transfer laminated using hand pressure to a 12.7 millimeter (0.5
inch) thick piece of plywood substrate. Next, the elastic
self-sealing air and water barrier article was stretched until it
was flat then laminated by hand to the plywood substrate such that
the exposed surface of the porous layer covered the pressure
sensitive adhesive layer. The plywood substrate having an adhesive
coated, elastic self-sealing air and water barrier article thereon
was then evaluated for nail sealability using test method 1.
[0201] Measurement of moisture vapor transmission rates and tensile
and elongation properties were conducted on the elastic
self-sealing air and water barrier article (continuous layer of
polymeric material on one side of the elastic porous layer) that
resulted from removal of the liner from the polymeric coating prior
to testing.
Example 7
[0202] Example 1 was repeated with the following modifications. The
elastic porous layer used was SONTARA 8005.
Illustrative Example 8
[0203] Comparative Example 1 was repeated with the following
modifications. LINER 2 was used in place of LINER 1 and the liner
was provided with a flood coating of INK 1 on one side using a #0
Meyer bar followed by drying at room temperature to provide 100%
ink coverage of the liner. The polymeric material was then coated
over the ink flood coat.
Example 9
[0204] Example 4 was repeated with the following modifications.
LINER 2 was used in place of LINER 1. Nail sealability was tested
on the article with the liner. Moisture Vapor Transmission Rate was
measured on LINER 2 only and reported in Table 1, below.
Combination with the elastic porous layer and polymeric layer is
expected to decrease the Moisture Vapor Transmission Rate.
Illustrative Example 10
[0205] Comparative Example 1 was repeated with the following
modifications. LINER 3 was used in place of LINER 1 and the liner
was provided with a flood coating of INK 1 on one side using a #0
Meyer bar followed by drying at room temperature to provide 100%
ink coverage of the liner. The polymeric material was then coated
over the ink flood coat.
Example 11
[0206] Example 4 was repeated with the following modifications.
LINER 3 was used in place of LINER 1. Nail sealability was tested
on the article with the liner. Moisture Vapor Transmission Rate was
measured on LINER 3 only and reported in Table 1, below.
Combination with the elastic porous layer and polymeric layer is
expected to decrease the Moisture Vapor Transmission Rate.
Example 12
[0207] Example 4 was repeated with the following modifications.
LINER 4 was used in place of LINER 1 and the liner was provided
with a flood coating of INK 1 on one side using a #0 Meyer bar
followed by drying at room temperature to provide 100% ink coverage
of the liner. The polymeric material was then coated over the ink
flood coat.
Example 13
[0208] Example 4 was repeated with the following modifications.
LINER 4 was used in place of LINER 1. Nail sealability was tested
on the article with the liner. Moisture Vapor Transmission Rate was
measured on LINER 4 only and reported in Table 1, below.
Combination with the elastic porous layer and polymeric layer is
expected to decrease the Moisture Vapor Transmission Rate.
Illustrative Example 14
[0209] Comparative Example 1 was repeated with the following
modifications. LINER 5 was used in place of LINER 1 and the liner
was provided with a flood coating of INK 1 on one side using a #0
Meyer bar followed by drying at room temperature to provide 100%
ink coverage of the liner. The polymeric material was then coated
over the ink flood coat.
Example 15
[0210] Example 4 was repeated with the following modifications.
LINER 5 was used in place of LINER 1. Nail sealability was tested
on the article with the liner. Moisture Vapor Transmission Rate was
measured on LINER 5 only and reported in Table 1, below.
Combination with the elastic porous layer and polymeric layer is
expected to decrease the Moisture Vapor Transmission Rate.
Example 16
[0211] Example 4 was repeated with the following modifications.
LINER 6 was used in place of LINER 1 and the liner was provided
with a flood coating of INK 1 on one side using a #0 Meyer bar
followed by drying at room temperature to provide 100% ink coverage
of the liner. The polymeric material was then coated over the ink
flood coat.
Example 17
[0212] Example 4 was repeated with the following modifications.
LINER 6 was used in place of LINER 1. Nail sealability was tested
on the article with the liner. Moisture Vapor Transmission Rate was
measured on LINER 6 only and reported in Table 1, below.
Combination with the elastic porous layer and polymeric layer is
expected to decrease the Moisture Vapor Transmission Rate.
Example 18
[0213] Example 4 was repeated with the following modifications. 2.5
pbw of hydrophobic fumed silica, AEROSIL R202 were used instead of
1.25 pbw in the polymeric formulation, and LINER 3 was used in
place of LINER 1. This sample was tested only for Stress Relaxation
after LINER 3 was removed.
Example 19
[0214] Example 18 was repeated with the following modifications.
0.87 pbw of GENIOSIL XL 65 was used in place of DYNASYLAN VTMO.
This construction was tested only for Stress Relaxation, Water
Strike Through, and Water Absorption Capacity after LINER 3 was
removed.
Comparative Example 2
[0215] Example 18 was repeated with the following modifications.
REEMAY 2024 was used as the porous layer. This sample was tested
for Water Strike Through and Water Absorption Capacity.
Results
TABLE-US-00002 [0216] TABLE 1 Nail Sealability (Test 1) and
Moisture Vapor Transmission Rate Nail Sealability Moisture Vapor
Transmission Rate Ex. Top Side Bottom Side Permeance No. Test 1
Test 1 (Perms) 1 A A 17.5 2 A A ND 3 A A ND 4 A A 31.9 CE 1 A A
22.7 6 A A 23.8 7 A A 23.1 9 A A Less than 0.85 11 A A Less than
0.91 12 A A 19.8 13 B A Less than 0.72 15 A A Less than 0.6 16 A A
21.3 17 A A Less than 0.4 Moisture Vapor Transmission Rate CE:
Comparative Example ND: Not Determined
TABLE-US-00003 TABLE 2 180.degree. Angle Peel Adhesion After 7 Days
at 23.degree. C./50% RH Ex. Tight Side Release Easy Side Release
No. (oz/in, N/dm) (oz/in, N/dm) 1 11.6 (12.7) NA CE 1 13.95 (15.3)
NA 5 NA 0.9 (1.0) 7 9.2 (10.1) NA 8 11.9 (13.0) NA 9 Cohesive
Failure NA 10 15.3 (16.7) NA 11 Cohesive Failure NA 12 3.7 (4.1) NA
13 Cohesive Failure NA 14 9.7 (10.6) NA 15 Cohesive Failure NA 16
3.4 (3.8) NA 17 38.9 (42.6) NA CE: Comparative Example NA: not
applicable
[0217] The results for Illustrative Example 5 in Table 2 are
typical of the Easy Side Release values for all the examples where
the same adhesive and liner are employed.
TABLE-US-00004 TABLE 3 180.degree. Angle Peel Adhesion After 7 Days
at 70.degree. C. Ex. No. Tight Side Release (oz/in, N/dm) 1 17.2
(18.8) CE 1 Cohesive Failure 7 16.1 (17.6) 12 5.9 (6.6) 16 3.3
(3.7) CE: Comparative Example
TABLE-US-00005 TABLE 4 180.degree. Angle Peel Adhesion After 7 Days
at 32.degree. C./90% RH Ex. No. Tight Side Release (oz/in, N/dm) 1
15.0 (16.4) CE 1 26.4 (28.9) 7 8.1 (8.9) CE: Comparative
Example
TABLE-US-00006 TABLE 5 Elongation Ex. No. Web Direction (CD or MD)
Elongation (%) 1 MD 111.4 4 CD 210.1 CE 1 MD 39.7 CE 1 CD 47.2 6 MD
109.9 7 CD 92.4 CE: Comparative Example
TABLE-US-00007 TABLE 6 Stress Relaxation Load after Web Direction
Initial Load lbf 5 minutes Stress Relaxation Ex. No. (CD or MD) (N)
lbf (N) (%) 4 MD 6.0 (26.5) 3.0 (13.1) 50% 18 MD 3.9 (17.4) 2.3
(10.3) 41% 19 MD 1.7 (7.7) 1.0 (4.5) 41%
TABLE-US-00008 TABLE 7 Water Strike Through Absorbance Ex. Strike
Through Initial Weight Final Weight Capacity No. Time (seconds)
(grams) (grams) (grams) CE1 1620 ND ND ND 4 296 5.13 6.4176 1.29 19
47.6 6.3384* 8.421* 2.08 CE 2 3300 3.9083 4.1999 0.2916 *Liner was
not removed prior to testing.
[0218] While the specification has described in detail certain
embodiments, it will be appreciated that those skilled in the art,
upon attaining an understanding of the foregoing, may readily
conceive of alterations to, variations of, and equivalents to these
embodiments. Accordingly, it should be understood that this
disclosure is not to be unduly limited to the illustrative
embodiments set forth hereinabove. Furthermore, all published
patent applications and issued patents referenced herein are
incorporated by reference in their entirety to the same extent as
if each individual publication or patent was specifically and
individually indicated to be incorporated by reference. Various
exemplary embodiments have been described. These and other
embodiments are within the scope of the following listing of
disclosed embodiments.
* * * * *